Aerosol delivery device with segmented electrical heater

ABSTRACT

The present disclosure provides an aerosol delivery device. In various implementations, the aerosol delivery device comprises a control body having an outer housing, an electrical energy source located within the housing, a control component operatively connected to the electrical energy source, a heating assembly operatively connected to the control component, and an aerosol source member that includes an aerosol generating component configured to be positioned proximate the heating assembly. The heating assembly comprises a series of heating members, and each heating member is independent and distinct and configured to heat a segment of the aerosol source member.

FIELD OF THE DISCLOSURE

The present disclosure relates to aerosol delivery articles and usesthereof for yielding tobacco components or other materials in aninhalable form. The articles may be made or derived from tobacco orotherwise incorporate tobacco for human consumption. More particularly,the disclosure provides aerosol delivery devices wherein tobacco, atobacco derived material, or other material is heated, preferablywithout significant combustion, to provide an inhalable substance, thesubstance, in the various implementations, being in a vapor or aerosolform. The present disclosure also relates to aerosol delivery devicesthat include a reservoir and a vaporizing assembly, which may utilizeelectrical power to heat an aerosol precursor composition for theproduction of an aerosol.

BACKGROUND

Many smoking articles have been proposed through the years asimprovements upon, or alternatives to, smoking products based uponcombusting tobacco. Example alternatives have included devices wherein asolid or liquid fuel is combusted to transfer heat to tobacco or whereina chemical reaction is used to provide such heat source. Examplesinclude the smoking articles described in U.S. Pat. No. 9,078,473 toWorm et al., which is incorporated herein by reference in its entirety.

The point of the improvements or alternatives to smoking articlestypically has been to provide the sensations associated with cigarette,cigar, or pipe smoking, without delivering considerable quantities ofincomplete combustion and pyrolysis products. To this end, there havebeen proposed numerous smoking products, flavor generators, andmedicinal inhalers which utilize electrical energy to vaporize or heat avolatile material, or attempt to provide the sensations of cigarette,cigar, or pipe smoking without burning tobacco to a significant degree.See, for example, the various alternative smoking articles, aerosoldelivery devices and heat generating sources set forth in the backgroundart described in U.S. Pat. No. 7,726,320 to Robinson et al.; and U.S.Pat. App. Pub. Nos. 2013/0255702 to Griffith, Jr. et al.; and2014/0096781 to Sears et al., which are incorporated herein by referencein their entireties. See also, for example, the various types of smokingarticles, aerosol delivery devices, and electrically powered heatgenerating sources referenced by brand name and commercial source inU.S. Pat. App. Pub. No. 2015/0220232 to Bless et al., which isincorporated herein by reference in its entirety. Additional types ofsmoking articles, aerosol delivery devices and electrically powered heatgenerating sources referenced by brand name and commercial source arelisted in U.S. Pat. App. Pub. No. 2015/0245659 to DePiano et al., whichis also incorporated herein by reference in its entirety. Otherrepresentative cigarettes or smoking articles that have been describedand, in some instances, been made commercially available include thosedescribed in U.S. Pat. No. 4,735,217 to Gerth et al.; U.S. Pat. Nos.4,922,901, 4,947,874, and 4,947,875 to Brooks et al.; U.S. Pat. No.5,060,671 to Counts et al.; U.S. Pat. No. 5,249,586 to Morgan et al.;U.S. Pat. No. 5,388,594 to Counts et al.; U.S. Pat. No. 5,666,977 toHiggins et al.; U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat. No.6,164,287 to White; U.S. Pat. No. 6,196,218 to Voges; U.S. Pat. No.6,810,883 to Felter et al.; U.S. Pat. No. 6,854,461 to Nichols; U.S.Pat. No. 7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi; U.S.Pat. No. 7,726,320 to Robinson et al.; U.S. Pat. No. 7,896,006 toHamano; U.S. Pat. No. 6,772,756 to Shayan; U.S. Pat. App. Pub. No.2009/0095311 to Hon; U.S. Pat. App. Pub. Nos. 2006/0196518,2009/0126745, and 2009/0188490 to Hon; U.S. Pat. App. Pub. No.2009/0272379 to Thorens et al.; U.S. Pat. App. Pub. Nos. 2009/0260641and 2009/0260642 to Monsees et al.; U.S. Pat. App. Pub. Nos.2008/0149118 and 2010/0024834 to Oglesby et al.; U.S. Pat. App. Pub. No.2010/0307518 to Wang; and WO 2010/091593 to Hon, which are incorporatedherein by reference in their entireties.

Representative products that resemble many of the attributes oftraditional types of cigarettes, cigars or pipes have been marketed asACCORD® by Philip Morris Incorporated; ALPHA™, JOYE 510™ and M4™ byInnoVapor LLC; CIRRUS™ and FLING™ by White Cloud Cigarettes; BLU™ byFontem Ventures B.V.; COHITA™, COLIBRI™, ELITE CLASSIC™, MAGNUM™,PHANTOM™ and SENSE™ by EPUIFFER® International Inc.; DUOPRO™, STORM™ andVAPORKING® by Electronic Cigarettes, Inc.; EGAR™ by Egar Australia;eGo-C™ and eGo-T™ by Joyetech; ELUSION™ by Elusion UK Ltd; EONSMOKE® byEonsmoke LLC; FIN™ by FIN Branding Group, LLC; SMOKE® by Green SmokeInc. USA; GREENARETTE™ by Greenarette LLC; HALLIGAN™ HENDU™ JET™, MAXXQ™PINK™ and PITBULL™ by SMOKE STIK®; HEATBAR™ by Philip MorrisInternational, Inc.; HYDRO IMPERIAL™ and LXE™ from Crown7; LOGIC™ andTHE CUBAN™ by LOGIC Technology; LUCI® by Luciano Smokes Inc.; METRO® byNicotek, LLC; NJOY® and ONEJOY™ by Sottera, Inc.; NO. 7™ by SS ChoiceLLC; PREMIUM ELECTRONIC CIGARETTE™ by PremiumEstore LLC; RAPP E-MYSTICK™by Ruyan America, Inc.; RED DRAGON™ by Red Dragon Products, LLC; RUYAN®by Ruyan Group (Holdings) Ltd.; SF® by Smoker Friendly International,LLC; GREEN SMART SMOKER® by The Smart Smoking Electronic CigaretteCompany Ltd.; SMOKE ASSIST® by Coastline Products LLC; SMOKINGEVERYWHERE® by Smoking Everywhere, Inc.; V2CIGS™ by VMR Products LLC;VAPOR NINE™ by VaporNine LLC; VAPOR4LIFE® by Vapor 4 Life, Inc.; VEPPO™by E-CigaretteDirect, LLC; VUSE® by R. J. Reynolds Vapor Company; MisticMenthol product by Mistic Ecigs; and the Vype product by CN CreativeLtd; IQOS™ by Philip Morris International; and GLO™ by British AmericanTobacco. Yet other electrically powered aerosol delivery devices, and inparticular those devices that have been characterized as so-calledelectronic cigarettes, have been marketed under the tradenames COOLERVISIONS™; DIRECT E-CIG™; DRAGONFLY™; EMIST™; EVERSMOKE™; GAMUCCI®;HYBRID FLAME™; KNIGHT STICKS™; ROYAL BLUES™; SMOKETIP®; and SOUTH BEACHSMOKE™;

Articles that produce the taste and sensation of smoking by electricallyheating tobacco, tobacco derived materials, and/or liquids have sufferedfrom inconsistent performance characteristics. Accordingly, it isdesirable to provide a smoking article that can provide the sensationsof cigarette, cigar, or pipe smoking, and that does so with advantageousperformance characteristics.

BRIEF SUMMARY

In various implementations, the present disclosure provides an aerosoldelivery device. In one implementation, the aerosol delivery devicecomprises a control body having an outer housing, an electrical energysource located within the housing, a control component operativelyconnected to the electrical energy source, a heating assemblyoperatively connected to the control component, and an aerosol sourcemember that includes an aerosol generating component configured to bepositioned proximate the heating assembly. The heating assemblycomprises a series of heating members, and each heating member isindependent and distinct and configured to heat a segment of the aerosolsource member. In some implementations, the heating assembly maycomprise a moveable jaw and a stationary jaw, wherein the heatingmembers are located on the moveable jaw, and wherein the moveable jawmay be configured to move between an open position, in which themoveable jaw is spaced from the stationary jaw and the heating membersare not in contact with the aerosol source member, and a closedposition, in which the series of heating members of the moveable jaw arein contact with the aerosol source member. Some implementations mayfurther comprise a receiving sleeve configured to receive the aerosolsource member, and the receiving sleeve may be located, in the closedposition, between the moveable jaw and the stationary jaw. In someimplementations, the series of heating members may comprise a series ofheating pins that are configured, in the closed position, to passthrough the aerosol source member and to create an electrical connectionwith a series of corresponding connectors located on the stationary jaw.In some implementations, the heating pins may have a substantiallycylindrical shape. In some implementations, the series of heatingmembers may comprise individual heating elements that are configured, inthe closed position, to extend into the aerosol source member. In someimplementations, the heating elements may have a substantiallyblade-like shape. In some implementations, the moveable jaw may beconfigured to be automatically moveable. In some implementations, themoveable jaw may be configured to be manually moveable.

In some implementations, the series of heating members may comprise aseries of individual heating elements, wherein the heating assembly maycomprise two or more moveable jaws, wherein one or more of the heatingmembers are located on each moveable jaw, and wherein the moveable jawsmay be configured to move between an open position, in which themoveable jaws are spaced from each other and the heating members are notin contact with the aerosol source member, and a closed position, inwhich the series of heating elements of the respective moveable jaws arein contact with the aerosol source member. In some implementations, theheating assembly may comprise three moveable jaws, and the heatingelements of each moveable jaw may have a staggered configuration withrespect to another moveable jaw. In some implementations, the heatingelements may be configured, in the closed position, to extend into theaerosol source member. In some implementations, the moveable jaws may beconfigured to be automatically moveable. In some implementations, themoveable jaws may be configured to be manually moveable. In someimplementations, the heating assembly may comprises a series of fixedheating elements that are located adjacent the aerosol source member. Insome implementations, the aerosol source member may comprise a removablecartridge and the aerosol generating component may comprise a tobacco ortobacco-derived material. In some implementations, the aerosol sourcemember may comprise a removable cartridge and the aerosol generatingcomponent may comprise a liquid aerosol precursor composition. In someimplementations, the cartridge may define a series of atomizer chambers,and a separate wick may extend through each atomizer chamber. In someimplementations, each of the fixed heating elements may be configured tobe located proximate a corresponding atomizer chamber. In someimplementations, the heating members may be configured to beindependently controllable.

These and other features, aspects, and advantages of the disclosure willbe apparent from a reading of the following detailed descriptiontogether with the accompanying drawings, which are briefly describedbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to assist the understanding of implementations of thedisclosure, reference will now be made to the appended drawings, inwhich like reference numerals refer to like elements and which are notnecessarily drawn to scale. The drawings are by way of example only andshould not be construed as limiting the disclosure.

FIG. 1 illustrates a perspective schematic view of an aerosol deliverydevice, in accordance with an example implementation of the presentdisclosure;

FIG. 2 illustrates a front schematic view of an aerosol delivery device,in accordance with an example implementation of the present disclosure;

FIG. 3 illustrates a perspective view of certain components of a heatingassembly of an aerosol delivery device, in accordance with an exampleimplementation of the present disclosure;

FIG. 4 illustrates a perspective view of certain components of a heatingassembly and an aerosol source member of an aerosol delivery device, inaccordance with an example implementation of the present disclosure;

FIG. 5 illustrates a perspective view of a component of a heatingassembly of an aerosol delivery device, in accordance with an exampleimplementation of the present disclosure;

FIG. 6 illustrates top and perspective views of certain components of aheating assembly of an aerosol delivery device in an open position, inaccordance with an example implementation of the present disclosure;

FIG. 7 illustrates a bottom view of certain components of a heatingassembly of an aerosol source member shown in an open position and aclosed position, in accordance with an example implementation of thepresent disclosure;

FIG. 8 illustrates a perspective view of an aerosol delivery device, inaccordance with an example implementation of the present disclosure;

FIG. 9 illustrates a perspective exploded view of an aerosol deliverydevice, in accordance with an example implementation of the presentdisclosure;

FIG. 10 illustrates a perspective view of an aerosol source member, inaccordance with an example implementation of the present disclosure;

FIG. 11 illustrates a perspective exploded view of an aerosol sourcemember, in accordance with an example implementation of the presentdisclosure; and

FIG. 12 illustrates a perspective view of a cartridge of an aerosolsource member, in accordance with an example implementation of thepresent disclosure.

DETAILED DESCRIPTION

The present disclosure now will be described more fully hereinafter.This disclosure may, however, be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein;rather, these embodiments are provided so that this disclosure will bethorough and complete, and will fully convey the scope of the disclosureto those skilled in the art. It must be noted that, as used in thisspecification, the singular forms “a,” “an,” and “the” include pluralreferents unless the context clearly dictates otherwise.

The present disclosure provides articles that use electrical energy toheat a material (preferably without combusting the material to anysignificant degree) to form an inhalable substance, the articles beingsufficiently compact to be considered “hand-held” devices. In certainimplementations, the articles can particularly be characterized assmoking articles. As used herein, the term is intended to mean anarticle that provides the taste and/or the sensation (e.g., hand-feel ormouth-feel) of smoking a cigarette, cigar, or pipe without the actualcombustion of any component of the article. The term smoking articledoes not necessarily indicate that, in operation, the article producessmoke in the sense of the by-product of combustion or pyrolysis. Rather,smoking relates to the physical action of an individual in using thearticle—e.g., holding the article in a hand, drawing on one end of thearticle, and inhaling from the article. In further implementations, theinventive articles can be characterized as being vapor-producingarticles, aerosolization articles, or pharmaceutical delivery articles.Thus, the articles can be arranged so as to provide one or moresubstances in an inhalable state. In some implementations, the inhalablesubstance can be substantially in the form of a vapor (i.e., a substancethat is in the gas phase at a temperature lower than its criticalpoint). In other implementations, the inhalable substance can be in theform of an aerosol (i.e., a suspension of fine solid particles or liquiddroplets in a gas). The physical form of the inhalable substance is notnecessarily limited by the nature of the inventive articles but rathermay depend upon the nature of the medium and the inhalable substanceitself as to whether it exists in a vapor state or an aerosol state. Insome implementations, the terms “vapor” and “aerosol” may beinterchangeable. Thus, for simplicity, the terms “vapor” and “aerosol”as used to describe the disclosure are understood to be interchangeableunless stated otherwise.

While the systems are generally described herein in terms ofimplementations associated with aerosol delivery devices such asso-called “e-cigarettes,” or “tobacco heating products,” it should beunderstood that the mechanisms, components, features, and methods may beembodied in many different forms and associated with a variety ofarticles. For example, the description provided herein may be employedin conjunction with implementations of traditional smoking articles(e.g., cigarettes, cigars, pipes, etc.), heat-not-burn cigarettes, andrelated packaging for any of the products disclosed herein. Accordingly,it should be understood that the description of the mechanisms,components, features, and methods disclosed herein are discussed interms of implementations relating to aerosol delivery devices by way ofexample only, and may be embodied and used in various other products andmethods.

Aerosol delivery devices of the present disclosure also can becharacterized as being vapor-producing articles or medicament deliveryarticles. Thus, such articles or devices can be adapted so as to provideone or more substances (e.g., flavors and/or pharmaceutical activeingredients) in an inhalable form or state. For example, inhalablesubstances can be substantially in the form of a vapor (i.e., asubstance that is in the gas phase at a temperature lower than itscritical point). Alternatively, inhalable substances can be in the formof an aerosol (i.e., a suspension of fine solid particles or liquiddroplets in a gas). For purposes of simplicity, the term “aerosol” asused herein is meant to include vapors, gases and aerosols of a form ortype suitable for human inhalation, whether or not visible, and whetheror not of a form that might be considered to be smoke-like.

In use, aerosol delivery devices of the present disclosure may besubjected to many of the physical actions employed by an individual inusing a traditional type of smoking article (e.g., a cigarette, cigar orpipe that is employed by lighting and inhaling tobacco). For example,the user of an aerosol delivery device of the present disclosure canhold that article much like a traditional type of smoking article, drawon one end of that article for inhalation of aerosol produced by thatarticle, take puffs at selected intervals of time, etc.

Aerosol delivery devices of the present disclosure generally include anumber of components provided within an outer shell or body. The overalldesign of the outer shell or body can vary, and the format orconfiguration of the outer body that can define the overall size andshape of the aerosol delivery device can vary. In some examples, anelongated body resembling the shape of a cigarette or cigar can beformed from a single, unitary shell; or the elongated body can be formedof two or more separable pieces. For example, an aerosol delivery devicecan comprise an elongated shell or body that can be substantiallytubular in shape and, as such, resemble the shape of a conventionalcigarette or cigar. Various other shapes and configurations may beemployed in other implementations (e.g., rectangular or fob-shaped).

In one implementation, all of the components of the aerosol deliverydevice are contained within one outer body or shell. Alternatively, anaerosol delivery device can comprise two or more shells that are joinedand are separable. For example, an aerosol delivery device can possess acontrol body comprising a shell containing one or more reusablecomponents (e.g., a rechargeable battery and various electronics forcontrolling the operation of that article), and removably attachedthereto a disposable portion (e.g., a disposable cartridge or aerosolsource member containing aerosol precursor material, flavorant, etc.).

In general, aerosol delivery devices of the present disclosure maygenerally comprise some combination of an electrical energy source(i.e., an electrical power source), at least one control component(e.g., means for actuating, controlling, regulating and ceasing powerfor heat generation, such as by controlling electrical current flow fromthe electrical energy source to other components of the device—e.g., amicroprocessor, individually or as part of a microcontroller), a heatingmember or heat generation component (e.g., a conductive electricalresistance heating member or an inductive heating member), and anaerosol source member that includes an aerosol generating component thatis positionable in proximity to or in direct contact with the heatingmember. When the heating member heats the aerosol generating component,an inhalable substance is formed from, released from, or generated fromthe aerosol generating component in a physical form suitable forinhalation by a consumer. It should be noted that the foregoing termsare meant to be interchangeable such that reference to release,releasing, releases, or released includes form or generate, forming orgenerating, forms or generates, and formed or generated. Specifically,the inhalable substance is released in the form of a vapor or aerosol ormixture thereof. It should be noted that the foregoing terms are meantto be interchangeable such that reference to release, releasing,releases, or released includes form or generate, forming or generating,forms or generates, and formed or generated. Specifically, an inhalablesubstance is released in the form of a vapor or aerosol or mixturethereof, wherein such terms are also interchangeably used herein exceptwhere otherwise specified.

As noted above, the aerosol delivery device may incorporate anelectrical energy source (e.g., a battery and/or other electrical powersource, such as a capacitor) to provide current flow sufficient toprovide various functionalities to the aerosol delivery device, such aspowering of a heating member, powering of control systems, powering ofindicators, and the like. The power source can take on variousimplementations. Preferably, the power source is able to deliversufficient power to rapidly heat the heating member to provide foraerosol formation and power the aerosol delivery device through use fora desired duration of time. The power source preferably is sized to fitconveniently within the aerosol delivery device so that the aerosoldelivery device can be easily handled. Additionally, a preferred powersource is of a sufficiently light weight to not detract from a desirablesmoking experience.

More specific formats, configurations and arrangements of componentswithin the single shell type of unit or within a multi-piece separableshell type of unit of the aerosol delivery device of the presentdisclosure will be evident in light of the further disclosure providedhereinafter. Additionally, the selection of various aerosol deliverydevice components can be appreciated upon consideration of thecommercially available electronic aerosol delivery devices. Further, thearrangement of the components within the aerosol delivery device canalso be appreciated upon consideration of the commercially availableelectronic aerosol delivery devices. Examples of commercially availableproducts, for which the components thereof, methods of operationthereof, materials included therein, and/or other attributes thereof maybe included in the devices of the present disclosure as well asmanufacturers, designers, and/or assignees of components and relatedtechnologies that may be employed in the aerosol delivery device of thepresent disclosure are described in U.S. patent application Ser. No.15/222,615, filed Jul. 28, 2016, to Watson et al., which is incorporatedherein by reference in its entirety.

Although a device according to the present disclosure may take on avariety of implementations, as discussed in detail below, the use of thedevice by a consumer will be similar in scope. In particular, the devicemay be provided as a plurality of components that are combined by theconsumer for use and then are dismantled by the consumer thereafter.Specifically, a consumer may have a reusable control body that issubstantially cylindrical, substantially rectangular, substantiallycuboidal, or another shape having an opening located in a portion of thecontrol body housing. In some implementations, the housing may alsoinclude one or more indicators of active use of the device (e.g., one ormore indicator lights, indicia displayed on an electronic display,haptic feedback, some combination thereof, etc.). In someimplementations, one or more aerosol source members may engage or may bereceived in the opening of the control body. To use the article, theconsumer may insert the aerosol source member into the opening orotherwise combine the aerosol source member with the control body sothat the device is operable as discussed herein. In someimplementations, the aerosol source member may be inserted as far intothe control body as allowed by the overall structure of the componentsand/or other internal receiving features. In some examples, at least aportion of the aerosol source member that is at least sufficiently sizedfor insertion into the mouth of the consumer for puffing thereon willremain outside of the control body. This may be referred to as the mouthend of the aerosol source member. In other examples a portion of theaerosol delivery device itself may be at least sufficiently sized forinsertion into the mouth of the consumer. This may be referred to as themouth end of the aerosol delivery device.

During use, the consumer initiates heating of a heating member that isadjacent an aerosol generating component (or a specific portion thereof)of the aerosol source member, and heating of the component releases theinhalable substance within a space inside the housing and/or the aerosolsource member so as to yield an inhalable substance. When the consumerinhales on the mouth end of the aerosol source member or the mouth endof the aerosol delivery device, air is drawn into and/or past theaerosol source member (such as, for example, through openings in theaerosol delivery device and/or the aerosol source member itself). Thecombination of the drawn air and the released inhalable substance isinhaled by the consumer as the drawn materials exit the mouth end of theaerosol source member or the mouth end of the aerosol delivery deviceinto the mouth of the consumer. In some implementations, to initiateheating, the consumer may manually actuate a pushbutton or similarcomponent that causes the heating member to receive electrical energyfrom the battery or other power source. The electrical energy may besupplied for a pre-determined length of time or may be manuallycontrolled. Preferably, flow of electrical energy does not substantiallyproceed in between puffs on the device (although energy flow may proceedto maintain a baseline temperature greater than ambienttemperature—e.g., a temperature that facilitates rapid heating to theactive heating temperature). In other implementations, heating may beinitiated by the puffing action of the consumer through use of varioussensors, as otherwise described herein. Once the puff is discontinued,heating may stop or be reduced. When the consumer has taken a sufficientnumber of puffs so as to have released a sufficient amount of theinhalable substance (e.g., an amount sufficient to equate to a typicalsmoking experience), the aerosol source member may be removed from thecontrol body and discarded.

FIG. 1 illustrates a perspective view of an aerosol delivery device 100,in accordance with example implementations of the present disclosure. Inparticular, FIG. 1 depicts an aerosol delivery device 100 that includesa housing 102 and an aerosol source member 104. FIG. 2 illustrates afront view of the aerosol delivery device 100, wherein a portion of thehousing 102 has been removed to reveal some internal components thereof.In particular, the aerosol delivery device 100 of the depictedimplementation further includes an electrical energy source 106 (e.g., abattery, which may be rechargeable, and/or a rechargeablesupercapacitor), a control component, 108 (e.g., a microprocessor,individually or as part of a microcontroller, a printed circuit board(PCB) that includes a microprocessor and/or microcontroller, etc.), anda heating assembly 110. As will be discussed in more detail below, theheating assembly 110 of various implementations comprises a series ofindependent and distinct heating members, wherein each heating member isconfigured to heat a segment of the aerosol source member 104.

In various implementations, one or both of the control component 108 andthe electrical energy source 106 may be coupled with the housing 102.For the sake of the current application, the phrase “coupled with” whenused with respect to one component relative to another may encompassimplementations in which one component is located within anothercomponent and/or implementations wherein one component is separate butotherwise operatively connected to another component. For example, inthe depicted implementation, both the control component 108 and theelectrical energy source 106 are located within the housing 102;however, in other implementations one or both of the control component108 and the electrical energy source 106 may be separate components.Further information regarding the control component 108 and theelectrical energy source 106 is provided below.

In some implementations, the housing 102 may also include one or morepushbuttons configured to activate certain operations of the device 100,such as, for example, turning on the device and initiating heating ofthe heating assembly 110 (e.g., one or more heating members of theheating assembly). As will be discussed in more detail below, in variousimplementations, the aerosol source member 104 may comprise a heatedend, which is configured to be inserted into the housing 102, and amouth end, upon which a user draws to create the aerosol. It should benoted that while the aerosol delivery device 100 of FIG. 1 is shown ashaving a substantially rectangular or fob-shaped housing 102 for ease ofillustration, in other implementations the housing 102 may have anyother shape including an elongated shell or body that may besubstantially tubular in shape and, as such, resemble the shape of aconventional cigarette or cigar, and thus the components described belowmay be sized and configured to fit inside an elongated body.

In specific implementations, one or both of the housing 102 and theaerosol source member 104 may be referred to as being disposable or asbeing reusable. For example, the electrical energy source 106 maycomprise a replaceable battery or a rechargeable battery, solid-statebattery, thin-film solid-state battery, rechargeable supercapacitor orthe like, and thus may be combined with any type of rechargingtechnology, including connection to a wall charger, connection to a carcharger (i.e., cigarette lighter receptacle), and connection to acomputer, such as through a universal serial bus (USB) cable orconnector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), connection to aphotovoltaic cell (sometimes referred to as a solar cell) or solar panelof solar cells, a wireless charger, such as a charger that usesinductive wireless charging (including for example, wireless chargingaccording to the Qi wireless charging standard from the Wireless PowerConsortium (WPC)), or a wireless radio frequency (RF) based charger. Anexample of an inductive wireless charging system is described in U.S.Pat. App. Pub. No. 2017/0112196 to Sur et al., which is incorporatedherein by reference in its entirety. Further, in some implementations,the aerosol source member 104 may comprise a single-use device. A singleuse component for use with a control body is disclosed in U.S. Pat. No.8,910,639 to Chang et al., which is incorporated herein by reference inits entirety.

In various implementations, the control component 108 may comprise acontrol circuit (which may be connected to further components, asfurther described herein) that may be connected by electricallyconductive wires to the electrical energy source 106. In variousimplementations, the control component 108 may control when and how theheating assembly 110 (e.g., one or more heating members of the heatingassembly) receives electrical energy to heat the aerosol generatingcomponent of the aerosol source member 104 for release of the inhalablesubstance for inhalation by a consumer. Such control can relate toactuation of pressure sensitive switches or the like, which aredescribed in greater detail hereinafter. It should be noted that theterms “connected” or “coupled” should not be read as necessitatingdirect connection without an intervening component. Rather, these termsmay encompass direct connection and/or connection via one or moreintervening components. As such, in various implementations these termsmay be understood to mean operatively connected to or operativelycoupled with. In various implementations, the control component of thepresent disclosure may comprise the control components and methodsdescribed in U.S. patent application Ser. No. 15/976,526, filed on May10, 2018, and titled Control Component for Segmented Heating in anAerosol Delivery Device, which is incorporated herein by reference inits entirety.

In some implementations, the control component 108 may be configured toclosely control the amount of heat provided to the aerosol generatingcomponent. While the heat needed to volatilize the aerosol-formingsubstance in a sufficient volume to provide a desired dosing of theinhalable substance for a single puff can vary for each particularsubstance used, it can be particularly useful for the heating assemblyto heat to a temperature of at least 120° C., at least 130° C., or atleast 140° C. In some implementations, in order to volatilize anappropriate amount of the aerosol-forming substance and thus provide adesired dosing of the inhalable substance, the heating temperature maybe at least 150° C., at least 200° C., at least 300° C., or at least350° C. It can be particularly desirable, however, to avoid heating totemperatures substantially in excess of about 550° C. in order to avoiddegradation and/or excessive, premature volatilization of theaerosol-forming substance. It should be noted that in someimplementations, the heating process may include different stages. Forexample, some implementations may include a preheating stage in whichthe heating assembly (e.g., each of the individual heating elements) mayheat to approximately 100° C. Then, depending on activation of anyindividual heater (e.g., such as being activated by push button, etc.)the temperature of that specific heater may increase as noted above.Heating specifically should be at a sufficiently low temperature andsufficiently short time so as to avoid significant combustion(preferably any combustion) of the aerosol generating component. Thepresent disclosure may particularly provide the components of thepresent article in combinations and modes of use that will yield theinhalable substance in desired amounts at relatively low temperatures.As such, yielding can refer to one or both of generation of the aerosolwithin the article and delivery out of the article to a consumer. Inspecific implementations, the heating temperature may be about 120° C.to about 300° C., about 130° C. to about 290° C., about 140° C. to about280° C., about 150° C. to about 250° C., or about 160° C. to about 200°C. The duration of heating can be controlled by a number of factors, asdiscussed in greater detail hereinbelow. Heating temperature andduration may depend upon the desired volume of aerosol and ambient airthat is desired to be drawn through the aerosol source member, asfurther described herein. The duration, however, may be varied dependingupon the heating rate of the heating assembly, as the article may beconfigured such that the heating members are energized only until adesired temperature is reached. Alternatively, duration of heating maybe coupled to the duration of a puff on the article by a consumer.Generally, the temperature and time of heating will be controlled by oneor more components contained in the control body, as noted above.

The amount of inhalable material released by the aerosol source membercan vary based upon the nature of the aerosol generating component.Preferably, the aerosol source member is configured with a sufficientamount of the aerosol generating component, with a sufficient amount ofany aerosol-former, and to function at a sufficient temperature for asufficient time to release a desired amount over a course of use. Theamount may be provided in a single inhalation from the aerosol sourcemember or may be divided so as to be provided through a number of puffsfrom the article over a relatively short length of time (e.g., less than30 minutes, less than 20 minutes, less than 15 minutes, less than 10minutes, or less than 5 minutes). For example, the device may providenicotine in an amount of about 0.01 mg to about 0.1 mg, about 0.05 mg toabout 1.0 mg, about 0.08 mg to about 0.5 mg, about 0.1 mg to about 0.3mg, or about 0.15 mg to about 0.25 mg per puff on the aerosol sourcemember. In other implementations, a desired amount may be characterizedin relation to the amount of wet total particulate matter deliveredbased on puff duration and volume. For example, the aerosol sourcemember may deliver at least 1.0 mg of wet total particulate matter oneach puff, for a defined number of puffs (as otherwise describedherein), when smoked under standard FTC smoking conditions of 2 second,35 ml puffs. Such testing may be carried out using any standard smokingmachine. In other implementations, the amount of total particulatematter (TPM) yielded under the same conditions on each puff may be atleast 1.5 mg, at least 1.7 mg, at least 2.0 mg, at least 2.5 mg, atleast 3.0 mg, about 1.0 mg to about 5.0 mg, about 1.5 mg to about 4.0mg, about 2.0 mg to about 4.0 mg, or about 2.0 mg to about 3.0 mg, atleast 3 mg to about 7 mg, about 4 mg to about 8 mg, and about 5 mg toabout 10 mg.

As noted, the aerosol delivery device 100 of some implementations mayinclude a pushbutton, which may be linked to the control component formanual control of the heating members. For example, in someimplementations the consumer may use the pushbutton to energize theheating assembly 110. Similar functionality tied to the pushbutton maybe achieved by other mechanical means or non-mechanical means (e.g.,magnetic or electromagnetic). Thusly, activation of the heating assembly110 may be controlled by a single pushbutton. Alternatively, multiplepushbuttons may be provided to control various actions separately. Insome implementations, one or more pushbuttons present may besubstantially flush with the casing of the housing 102.

Instead of (or in addition to) any pushbuttons, the aerosol deliverydevice 100 of the present disclosure may include components thatenergize the heating assembly 110 in response to the consumer's drawingon the article (i.e., puff-actuated heating). For example, the devicemay include a switch or flow sensor (not shown) in the housing 102 thatis sensitive either to pressure changes or air flow changes as theconsumer draws on the article (i.e., a puff-actuated switch). Othersuitable current actuation/deactuation mechanisms may include atemperature actuated on/off switch or a lip pressure actuated switch, ora touch sensor (e.g., capacitive touch sensor) configured to sensecontact between a user (e.g., mouth or fingers of user) and one or moresurfaces of the aerosol delivery device 100. An example mechanism thatcan provide such puff-actuation capability includes a Model 163PC01D36silicon sensor, manufactured by the MicroSwitch division of Honeywell,Inc., Freeport, Ill. With such sensor, the heating member may beactivated rapidly by a change in pressure when the consumer draws on thedevice. In addition, flow sensing devices, such as those using hot-wireanemometry principles, may be used to cause the energizing of theheating assembly sufficiently rapidly after sensing a change in airflow. A further puff actuated switch that may be used is a pressuredifferential switch, such as Model No. MPL-502-V, range A, from MicroPneumatic Logic, Inc., Ft. Lauderdale, Fla. Another suitable puffactuated mechanism is a sensitive pressure transducer (e.g., equippedwith an amplifier or gain stage) which is in turn coupled with acomparator for detecting a predetermined threshold pressure. Yet anothersuitable puff actuated mechanism is a vane which is deflected byairflow, the motion of which vane is detected by a movement sensingmeans. Yet another suitable actuation mechanism is a piezoelectricswitch. Also useful is a suitably connected Honeywell MicroSwitchMicrobridge Airflow Sensor, Part No. AWM 2100V from MicroSwitch Divisionof Honeywell, Inc., Freeport, Ill. Further examples of demand-operatedelectrical switches that may be employed in a heating circuit accordingto the present disclosure are described in U.S. Pat. No. 4,735,217 toGerth et al., which is incorporated herein by reference in its entirety.Other suitable differential switches, analog pressure sensors, flow ratesensors, or the like, will be apparent to the skilled artisan with theknowledge of the present disclosure. In some implementations, apressure-sensing tube or other passage providing fluid connectionbetween the puff actuated switch and aerosol source member 104 may beincluded in the housing 102 so that pressure changes during draw arereadily identified by the switch. Other example puff actuation devicesthat may be useful according to the present disclosure are disclosed inU.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,874, all to Brooks etal., U.S. Pat. No. 5,372,148 to McCafferty et al., U.S. Pat. No.6,040,560 to Fleischhauer et al., U.S. Pat. No. 7,040,314 to Nguyen etal., and U.S. Pat. No. 8,205,622 to Pan, all of which are incorporatedherein by reference in their entireties. Reference also is made to thecontrol schemes described in U.S. Pat. No. 9,423,152 to Ampolini et al.,which is incorporated herein by reference in its entirety.

In some implementations, when the consumer draws on the mouth end of theaerosol source member 104, the current actuation means may permitunrestricted or uninterrupted flow of current through the heatingassembly to generate heat rapidly. Because of the rapid heating, it canbe useful to include current regulating components to (i) regulatecurrent flow through the heating assembly to control heating of theheating assembly and the temperature experienced thereby, and (ii)prevent overheating and degradation of the aerosol generating component.In some implementations, the current regulating circuit may betime-based. Specifically, such a circuit may include a means forpermitting uninterrupted current flow through the heating member for aninitial time period during draw, and a timer means for subsequentlyregulating current flow until draw is completed. For example, thesubsequent regulation can include the rapid on-off switching of currentflow (e.g., on the order of about every 1 to 50 milliseconds) tomaintain the heating assembly (or one or more heating members of theheating assembly) within the desired temperature range. Further,regulation may comprise simply allowing uninterrupted current flow untilthe desired temperature is achieved then turning off the current flowcompletely. The heating assembly (or one or more heating members of theheating assembly) may be reactivated by the consumer initiating anotherpuff on the article (or manually actuating the pushbutton, dependingupon the specific switch implementation employed for activating theheater). Alternatively, the subsequent regulation can involve themodulation of current flow through the heating assembly (or one or moreheating members of the heating assembly) to maintain the heatingassembly (or one or more heating members of the heating assembly) withina desired temperature range. In some implementations, so as to releasethe desired dosing of the inhalable substance, the heating assembly (orone or heating members of the heating assembly) may be energized for aduration of about 0.2 second to about 5.0 seconds, about 0.3 second toabout 4.0 seconds, about 0.4 second to about 3.0 seconds, about 0.5second to about 2.0 seconds, or about 0.6 second to about 1.5 seconds.One example time-based current regulating circuit can include atransistor, a timer, a comparator, and a capacitor. Suitabletransistors, timers, comparators, and capacitors are commerciallyavailable and will be apparent to the skilled artisan. Example timersare those available from NEC Electronics as C-1555C and from GeneralElectric Intersil, Inc. as ICM7555, as well as various other sizes andconfigurations of so-called “555 Timers”. An example comparator isavailable from National Semiconductor as LM311. Further description ofsuch time-based current regulating circuits is provided in U.S. Pat. No.4,947,874 to Brooks et al., which is incorporated herein by reference inits entirety.

In light of the foregoing, it can be seen that a variety of mechanismscan be employed to facilitate actuation/deactuation of current to theheating assembly (or one or more members of the heating assembly). Forexample, the device may include a timer for regulating current flow inthe article (such as during draw by a consumer). The device may furtherinclude a timer responsive switch that enables and disables current flowto the heating member. Current flow regulation also can comprise use ofa capacitor and components for charging and discharging the capacitor ata defined rate (e.g., a rate that approximates a rate at which theheating member heats and cools). Current flow specifically may beregulated such that there is uninterrupted current flow through theheating member for an initial time period during draw, but the currentflow may be turned off or cycled alternately off and on after theinitial time period until draw is completed. Such cycling may becontrolled by a timer, as discussed above, which can generate a presetswitching cycle. In specific implementations, the timer may generate aperiodic digital wave form. The flow during the initial time periodfurther may be regulated by use of a comparator that compares a firstvoltage at a first input to a threshold voltage at a threshold input andgenerates an output signal when the first voltage is equal to thethreshold voltage, which enables the timer. Such implementations furthercan include components for generating the threshold voltage at thethreshold input and components for generating the threshold voltage atthe first input upon passage of the initial time period.

Still further components can be utilized in the aerosol delivery deviceof the present disclosure. For example, U.S. Pat. No. 5,154,192 toSprinkel et al. discloses indicators for smoking articles; U.S. Pat. No.5,261,424 to Sprinkel, Jr. discloses piezoelectric sensors that can beassociated with the mouth-end of a device to detect user lip activityassociated with taking a draw and then trigger heating of a heatingdevice; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puffsensor for controlling energy flow into a heating load array in responseto pressure drop through a mouthpiece; U.S. Pat. No. 5,967,148 to Harriset al. discloses receptacles in a smoking device that include anidentifier that detects a non-uniformity in infrared transmissivity ofan inserted component and a controller that executes a detection routineas the component is inserted into the receptacle; U.S. Pat. No.6,040,560 to Fleischhauer et al. describes a defined executable powercycle with multiple differential phases; U.S. Pat. No. 5,934,289 toWatkins et al. discloses photonic-optronic components; U.S. Pat. No.5,954,979 to Counts et al. discloses means for altering draw resistancethrough a smoking device; U.S. Pat. No. 6,803,545 to Blake et al.discloses specific battery configurations for use in smoking devices;U.S. Pat. No. 7,293,565 to Griffen et al. discloses various chargingsystems for use with smoking devices; U.S. Pat. No. 8,402,976 toFernando et al. discloses computer interfacing means for smoking devicesto facilitate charging and allow computer control of the device; U.S.Pat. No. 8,689,804 to Fernando et al. discloses identification systemsfor smoking devices; and PCT Pat. App. Pub. No. WO 2010/003480 by Flickdiscloses a fluid flow sensing system indicative of a puff in an aerosolgenerating system; all of the foregoing disclosures being incorporatedherein by reference in their entireties. Another method uses anelectrical resistance change for actuating the aerosol delivery deviceand/or the heating assembly thereof. It works by using a very thin smallmetallic probe in the form of strip or wire that is installedperpendicular to the air flow inside the cartridge. The air flowgenerated by the user applies mechanical force on the probe and folds itto some extent. Due to this change in geometry that results inbending/tension in part of the probe, a change in electrical resistanceof the probe occurs, this resistance alteration is sent as apulse/information to the PCB and works as a trigger to activate theheating assembly 110.

Further examples of components related to electronic aerosol deliveryarticles and disclosing materials or components that may be used in thepresent article include U.S. Pat. No. 4,735,217 to Gerth et al.; U.S.Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No. 5,666,977 to Higginset al.; U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat. No. 6,164,287to White; U.S. Pat. No. 6,196,218 to Voges; U.S. Pat. No. 6,810,883 toFelter et al.; U.S. Pat. No. 6,854,461 to Nichols; U.S. Pat. No.7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi; U.S. Pat. No.7,896,006 to Hamano; U.S. Pat. No. 6,772,756 to Shayan; U.S. Pat. Nos.8,156,944 and 8,375,957 to Hon; U.S. Pat. No. 8,794,231 to Thorens etal.; U.S. Pat. No. 8,851,083 to Oglesby et al.; U.S. Pat. Nos. 8,915,254and 8,925,555 to Monsees et al.; U.S. Pat. No. 9,220,302 to DePiano etal.; U.S. Pat. App. Pub. Nos. 2006/0196518 and 2009/0188490 to Hon; U.S.Pat. App. Pub. No. 2010/0024834 to Oglesby et al.; U.S. Pat. App. Pub.No. 2010/0307518 to Wang; PCT Pat. App. Pub. No. WO 2010/091593 to Hon;and PCT Pat. App. Pub. No. WO 2013/089551 to Foo, each of which isincorporated herein by reference in its entirety. Further, U.S. patentapplication Ser. No. 14/881,392 to Worm et al., filed Oct. 13, 2015,discloses capsules that may be included in aerosol delivery devices andfob-shape configurations for aerosol delivery devices, and isincorporated herein by reference in its entirety. A variety of thematerials disclosed by the foregoing documents may be incorporated intothe present devices in various implementations, and all of the foregoingdisclosures are incorporated herein by reference in their entireties.

As noted above, the electrical energy source 106 used to provide powerto the various electrical components of the device 100 may take onvarious implementations. Preferably, the electrical energy source isable to deliver sufficient energy to rapidly heat the heating assemblyin the manner described above and power the device through use withmultiple aerosol source members 104 while still fitting conveniently inthe device 100. Examples of useful electrical energy sources includelithium-ion batteries that are preferably rechargeable (e.g., arechargeable lithium-manganese dioxide battery). In particular, lithiumpolymer batteries can be used as such batteries can provide increasedsafety. Other types of batteries—e.g., nickel-cadmium cells,lithium-metal cells, lithium-Sulphur batteries, lithium-air batteries,nanowire batteries, graphene batteries, foam batteries—may also be used.Additionally, a preferred electrical energy source is of a sufficientlylight weight to not detract from a desirable smoking experience. Someexamples of possible electrical energy sources are described in U.S.Pat. No. 9,484,155 to Peckerar et al., and U.S. Pat. App. Pub. No.2017/0112191 to Sur et al., filed Oct. 21, 2015, the disclosures ofwhich are incorporated herein by reference in their respectiveentireties.

One example of an electrical energy source is a TKI-1550 rechargeablelithium-ion battery produced by Tadiran Batteries GmbH of Germany. Inanother implementation, a useful electrical energy source may be aN50-AAA CADNICA nickel-cadmium cell produced by Sanyo Electric Company,Ltd., of Japan. In other implementations, a plurality of such batteries,for example providing 1.2-volts each, may be connected in series. Otherelectrical energy sources, such as rechargeable lithium-manganesedioxide batteries, may also be used. Any of these batteries orcombinations thereof may be used in the electrical energy source, butrechargeable batteries are preferred because of cost and disposalconsiderations associated with disposable batteries. In implementationswhere rechargeable batteries are used, the aerosol delivery device 100may further include charging contacts for interaction with correspondingcontacts in a conventional recharging unit (not shown) deriving powerfrom a standard 120-volt AC wall outlet, or other sources such as anautomobile electrical system or a separate portable power supply. Infurther implementations, the electrical energy source may also comprisea capacitor. Capacitors are capable of discharging more quickly thanbatteries and can be charged between puffs, allowing the battery todischarge into the capacitor at a lower rate than if it were used topower the heating member directly. For example, a supercapacitor—e.g.,an electric double-layer capacitor (EDLC)—may be used separate from orin combination with a battery. When used alone, the supercapacitor maybe recharged before each use of the device 100. Thus, the presentdisclosure also may include a charger component that can be attached tothe device between uses to replenish the supercapacitor. Thin filmbatteries may be used in certain implementations of the presentdisclosure.

As noted above, in various implementations, the aerosol delivery device100 may comprise one or more indicators (not shown). In variousimplementations, one or more indicators may be located at any locationon the housing 102. In some implementations, the indicators may belights (e.g., light emitting diodes) that may provide indication ofmultiple aspects of use of the device. For example, a series of lightsmay correspond to the number of puffs for a given aerosol source member.Specifically, the lights may successively become lit with each puff suchthat when all lights are lit, the consumer is informed that the aerosolsource member is spent. Alternatively, all lights may be lit upon theaerosol source member being inserted into the housing, and a light mayturn off with each puff, such that when all lights are off, the consumeris informed that the aerosol source member is spent. In otherimplementations, a series of lights might correspond to the series ofheating members, such that if one or more of the heating members isactivated, the corresponding light may be lit. In still otherimplementations, only a single indicator may be present, and lightingthereof may indicate that current is flowing to the heating assembly andthe device is actively heating. This may ensure that a consumer does notunknowingly leave the device unattended in an actively heating mode. Inalternative implementations, one or more of the indicators may be acomponent of the aerosol source member. Although the indicators aredescribed above in relation to visual indicators in an on/off method,other indices of operation also are encompassed. For example, visualindicators also may include changes in light color or intensity to showprogression of the smoking experience. Tactile indicators and audibleindicators similarly are encompassed by the present disclosure.Moreover, combinations of such indicators also may be used in a singledevice.

In various implementations, the housing 102 may be formed of anymaterial suitable for forming and maintaining an appropriateconformation, such as a tubular or rectangular shape, and for retainingtherein an aerosol source member. In some implementations, the housingmay be formed of a single wall, or multiple walls, and from a materialor multiple materials (natural or synthetic) that are heat resistant soas to retain its structural integrity—e.g., does not degrade—at least ata temperature that is the heating temperature provided by the electricalheating member, as further discussed herein. In some implementations, aheat resistant polymer may be used. In other implementations, ceramicmaterials may be used. In further implementations, an insulatingmaterial may be used so as not to unnecessarily move heat away from theaerosol source member. The housing, when formed of a single layer, mayhave a thickness that preferably is about 0.2 mm to about 5.0 mm, about0.5 mm to about 4.0 mm, about 0.5 mm to about 3.0 mm, or about 1.0 mm toabout 3.0 mm. Further example types of components and materials that maybe used to provide the functions described above or be used asalternatives to the materials and components noted above can be those ofthe types set forth in U.S. Pat. App. Pub. Nos. 2010/00186757 to Crookset al.; 2010/00186757 to Crooks et al.; and 2011/0041861 to Sebastian etal.; the disclosures of the documents being incorporated herein byreference in their entireties.

FIG. 3 illustrates a perspective view of certain components of theheating assembly 110 of the aerosol delivery device 100 of FIGS. 1 and2, in accordance with an example implementation of the presentdisclosure, and FIG. 4 illustrates a perspective view of certaincomponents of the heating assembly 110 with an aerosol source member 104located in the receiving sleeve 116, in accordance with an exampleimplementation of the present disclosure. In particular, the heatingassembly 110 of the depicted implementation includes a moveable jaw 112,a stationary jaw 114 (rotated upside down in the drawing, for clarity ofillustration), and a receiving sleeve 116. Although other materials arepossible, in the depicted implementation, the moveable jaw 112, thestationary jaw 114, and/or the receiving sleeve 116 may be made of metalmaterials (e.g., aluminum, stainless steel, metal alloys, etc.), ceramicmaterials (e.g., alumina, silica, mullite, silicon carbide, siliconnitride, aluminum nitride, etc.), polymers (e.g., polyimide,thermoplastic polyimide, polybenzimidazole, polyether ether ketone,polypropylene, high density polyethylene, etc.) composite materials,and/or any combinations thereof. As will be discussed in more detailbelow, the moveable jaw 112 of the depicted implementation is configuredto move between an open position, in which the moveable jaw is spacedfrom the stationary jaw 114 and the receiving sleeve 116, and a closedposition, in which the moveable jaw 112 is adjacent the stationary jaw114, and the receiving sleeve 116 is in between the moveable jaw 112 andthe stationary jaw 114. In the depicted implementation, the receivingsleeve 116 has a substantially cylindrical shape configured to receiveat least the heated end of the aerosol source member 104; however, inother implementations the receiving sleeve may have any other shape,such as any shape that is complementary of the shape of the heated endof the aerosol source member. In the depicted implementation, each ofthe moveable jaw 112 and the stationary jaw 114 has an internal shapeconfigured to substantially surround the receiving sleeve 116 and thusat least the heated end of the aerosol source member 104. In particular,an interior surface 118 of the moveable jaw 112 and an interior surface119 of the stationary jaw 114 together form a shape complementary of theshape of the receiving sleeve 116. In such a manner, when the moveablejaw 112 is in the closed position, the internal surfaces 118, 119 cometogether to surround the receiving sleeve 116.

The moveable jaw 112 of the depicted implementation includes a series ofheating pins 120, which extend outward from the internal surface 118thereof. The moveable jaw 112 of the depicted implementation alsoincludes a pair of locating pins 122, which extend outward from theinternal surface 118 of the moveable jaw 112. It should be noted that insome implementations there need not be any locating pins 122 as theheating pins may also serve this function. In various implementations,the series of heating pins 120 are configured to electrically connect(in the closed position) with a series of corresponding connectors 124,which are located on the internal surface 119 of the stationary jaw 114.In addition, the receiving sleeve 116 includes two opposing rows ofopenings 126, which, in operation, align with the series of heating pins120 and the series of connectors 124. In addition, a pair of endopenings 128 is configured to align with the locating pins 122. When themoveable jaw 112 is in in the closed position, the series of heatingpins 120 extend through corresponding openings 126 of the receivingsleeve 116 and into electrical contact with the corresponding connectors124 of the stationary jaw 120. The locating pins 122 of the depictedimplementation also extend through a pair of corresponding openings 128of the receiving sleeve but do not make electrical contact with thestationary jaw 114; however, in some implementations the locating pins122 may also make electrical contact. In the depicted implementation,there are seven heating pins 120 and thus there are seven correspondingconnectors 124 and seven corresponding openings 126; however, in otherimplementations any number of heating pins 120, connectors 124, andopenings 126 may be used. In the depicted implementation the heatingpins have a substantially cylindrical shape with a rounded end; however,in other implementations, the heating pins 120 may have other shapes,and in still other implementations, the heating pins 120 need not havethe same shape.

The heating pins 120 of the depicted implementation comprise resistiveheating members when the electrical connection is made with thecorresponding connectors 124. Resistive heating members may beconfigured to produce heat when an electrical current is directedtherethrough. Such heating members often comprise a metal material orelectrically conductive ceramics and are configured to produce heat as aresult of the electrical resistance associated with passing anelectrical current therethrough. While in some implementations, thematerial of the heating pins may be the same throughout, the heatingpins 120 of the depicted implementation include electrically conductivematerials on each end (e.g., the ends of the heating pins 120 thatcontact the connectors 124 and the ends of the heating pins 120connected to the control component 108 and/or electrical energy source106) and an electrically resistant material in between (e.g., theportion of the heating pins 120 that is configured to contact theaerosol forming component. Examples of the electrically resistantmaterials may include, but are not limited to, titanium, silver, nickel,nichrome, stainless steel, various metal alloys, ceramics such assilicon carbide and silicon nitride, composites, and/or any combinationthereof. Examples of the electrically conductive materials, may include,but are not limited to, copper, aluminum, platinum, gold, silver, iron,steel, brass, bronze, graphite, and/or any combination thereof. Avariety of conductive substrates that may be usable with the presentdisclosure are described in U.S. Pat. App. Pub. No. 2013/0255702 toGriffith et al., the disclosure of which is incorporated herein byreference in its entirety. In some implementations, the heating pins mayinclude resistive traces on the surfaces thereof. In suchimplementations, for example, the resistive traces may be added to thepins via a variety of techniques including, for example, molding,printing, embedding, machining, squeeze casting, vapor deposition, etc.

As noted, the receiving sleeve 116 of the depicted implementation isconfigured to receive the heated end of the aerosol source member 104,which may include an aerosol generating component 130. In the openposition (shown, for example, in FIG. 2), the moveable jaw 112 is spacedfrom the stationary jaw 114, as well as the receiving sleeve 116 andaerosol source member 104, and in the closed position (shown for examplein FIG. 4), the moveable jaw 112 is adjacent the stationary jaw 114,with the receiving sleeve 116 and aerosol source member 104 disposed inbetween. In various implementations, actuation between the open positionand the closed position (and vice versa) may be accomplished in avariety ways, including, for example, manually, such as by a consumerpressing the jaws together, or automatically or semi-automatically, suchas by using a hydraulic gas spring or other force-displacement mechanismthat transfers directional force to the moveable jaw 112. Anotherexample may include a linear displacement motor or other actuatorconfigured to displace the moveable jaw 112 between the open and closedpositions. Other examples include a piezo actuator, an ultrasonicceramic actuator, a rotating coil system, a lead screw system, a camfollower mechanism, a gear mechanism, a linkage, and/or any other systemconfigured for generating and transferring directional motion to themoveable jaw 112. Regardless of the mechanism, this motion may beactivated via a pushbutton and/or via use of the device (such as, forexample, by powering the device, by drawing on the aerosol sourcemember, or by inserting an aerosol source member into the device) assimilarly discussed above. In addition to those described above, anothermethod for actuating the moveable jaw 112 operates by means of a smallthin metallic probe, such as in the form of strip or wire, that isinstalled perpendicular to the air flow inside the device 100. The airflow generated by the user applies mechanical force on the probe andfolds or bends to some extent. Due to the change in the geometry thatresults in bending/tension of the probe, a change in electricalresistance of the probe occurs. This resistance alteration is sent as apulse and/or signal to the control component 108 and works as a triggerto activate the moveable jaw 112.

In the closed position, each heating pin 120 completes an electricalcircuit so as to create an independent and distinct heating circuit thatis capable of heating, via the heating pin 120, a segment of the aerosolsource member. In the open position, however, each circuit is incompleteand the heating pins are incapable of heating. In variousimplementations, the control component 108 may independently controleach of the heating circuits. In such a manner, in the closed position,each of the heating pins 120 may heat a segment of the aerosol sourcemember independently, as controlled by the control component 108.Therefore, in some applications the heating pins 120 may sequentiallyheat segments of the aerosol source member, while in other applicationsthe heating pins 120 may heat certain groups of segments of the aerosolsource member. As will be appreciated, the present disclosurecontemplates all of the different heating conditions afforded by usingindependently controlled heating pins 120. As will be discussed in moredetail below, in some implementations heating pin control may occur viathe user (such as, for example, via a push button or a control panel) onthe device. In addition, various indicators may also indicate whichheaters have been used and which heaters have not been used for aconsumable used in the device.

It should be noted that while in the depicted implementation there are atotal of seven distinct heating pins 120 corresponding to seven distinctheating segments of the aerosol source member 104, in various otherimplementations the heating assembly 110 may have any number of distinctheating members corresponding to any number of discrete heating segmentsof the aerosol source member. Further, while in the depictedimplementation there a plurality of discrete heating member positionsand corresponding discrete heating segments that are spaced apart fromeach other, in other implementations the discrete positions andcorresponding discrete segments may have different spacing, including,but not limited to, spacing that results in the discrete positions andcorresponding discrete segments abutting each other and/or overlappingeach other, as well as inconsistent spacing.

In the depicted implementation, the heating pins 120 are configured topierce through the aerosol generating component 130 of the aerosolsource member, which is contained in the aerosol source member 104received in the receiving sleeve 116, and make electrical contact withthe connectors 124 of the stationary jaw 114. As such, the aerosolgenerating component 130 of the depicted implementation comprises asolid or semi-solid material (such as, for example, a tobacco ortobacco-derived material, a medicinal material, an herbal material,etc.). In other implementations, however, the aerosol generatingcomponent may comprise a gel, liquid, or semi-liquid material.

As noted, in various implementations the aerosol generating componentmay comprise a solid or semi-solid material that may be a tobacco ortobacco-derived material. In some implementations, such a material maycomprise tobacco-containing beads, tobacco shreds, tobacco strips,reconstituted tobacco material (e.g., an extruded or caste sheetsubstrate), or combinations thereof, and/or a mix of finely groundtobacco, tobacco extract, spray dried tobacco extract, or other tobaccoform mixed with optional inorganic materials (such as calciumcarbonate), optional flavors, and aerosol forming materials to form asubstantially solid or moldable (e.g., extrudable) substrate. Gels andsuspensions may also be utilized. Some representative types of solid andsemi-solid aerosol generating component constructions and formulationsare disclosed in U.S. Pat. No. 8,424,538 to Thomas et al.; U.S. Pat. No.8,464,726 to Sebastian et al.; U.S. Pat. App. Pub. No. 2015/0083150 toConner et al.; U.S. Pat. App. Pub. No. 2015/0157052 to Ademe et al.; andU.S. Pat. App. Pub. No. 2017-0000188 to Nordskog et al., filed Jun. 30,2015, all of which are incorporated by reference herein.

In various implementations, the aerosol source member, or a portionthereof, may be wrapped in an overwrap material, which may be formed ofany material useful for providing additional structure and/or supportfor the aerosol source member. In various implementations, the overwrapmaterial may comprise a material that resists (or promotes) transfer ofheat, which may include a paper or other fibrous material, such as acellulose material. The overwrap material may also include at least onefiller material imbedded or dispersed within the fibrous material. Invarious implementations, the filler material may have the form of waterinsoluble particles. Additionally, the filler material can incorporateinorganic components. In various implementations, the overwrap may beformed of multiple layers, such as an underlying, bulk layer, and anoverlying layer, such as a typical wrapping paper in a cigarette. Suchmaterials may include, for example, lightweight “rag fibers” such asflax, hemp, sisal, rice straw, and/or esparto. Further discussionsrelating to the configurations for overwrap materials that may be usedwith the present disclosure may be found in U.S. Pat. No. 9,078,473 toWorm et al., which is incorporated herein by reference in its entirety.In additional implementations, the overwrap material may have or more ofthe following qualities: it may be impermeable to the transfer ofaerosol, it may have the ability to withstand the elevated temperatureunder consideration, it may promote the transfer of heat in the radialdirection from the heater to the tobacco stick material, it may resistthe transfer of heat in the axial direction along the tobacco stick awayfrom the segment being heated, and/or it may have relatively low thermalmass so that it does not inhibit rapid temperature rises of the segmentbeing heated. In one implementation, the overwrap material may be astainless steel foil that, in some implementations, may be approximately0.001″ thick. In another implementation, the overwrap material may be analuminum foil.

In various implementations, the mouth end of an aerosol source membermay include a filter, which may, for example, be made of a celluloseacetate, polypropylene, or polylactic acid material. In variousimplementations, the filter may increase the structural integrity of themouth end of the aerosol source member, and/or provide filteringcapacity, if desired, and/or provide resistance to draw. For example, anarticle according to the disclosure can exhibit a pressure drop of about50 to about 250 mm water pressure drop at 17.5 cc/second air flow. Infurther implementations, pressure drop can be about 60 mm water to about180 mm water or about 70 mm water to about 150 mm water. Pressure dropvalue may be measured using a Filtrona Filter Test Station (CTS Series)available from Filtrona Instruments and Automation Ltd or a Quality TestModule (QTM) available from the Cerulean Division of Molins, PLC. Thelength of the filter at the mouth end of the aerosol source member canvary—e.g., about 2 mm to about 20 mm, about 5 mm to about 20 mm, orabout 10 mm to about 15 mm. In some implementations, the filter maycomprise discrete segments. For example, some implementations mayinclude a segment providing filtering, a segment providing drawresistance, a hollow segment providing a space for the aerosol to cool,a segment providing increased structural integrity, other filtersegments, and any one or any combination of the above. In someimplementations, the filter may be separate from the overwrap, and thefilter may be held in position by the overwrap.

Additional example types of overwrapping materials, wrapping materialcomponents, and treated wrapping materials that may be used in overwrapin the present disclosure are described in U.S. Pat. No. 5,105,838 toWhite et al.; U.S. Pat. No. 5,271,419 to Arzonico et al.; U.S. Pat. No.5,220,930 to Gentry; U.S. Pat. No. 6,908,874 to Woodhead et al.; U.S.Pat. No. 6,929,013 to Ashcraft et al.; U.S. Pat. No. 7,195,019 toHancock et al.; U.S. Pat. No. 7,276,120 to Holmes; U.S. Pat. No.7,275,548 to Hancock et al.; PCT WO 01/08514 to Fournier et al.; and PCTWO 03/043450 to Hajaligol et al., which are incorporated herein byreference in their entireties. Representative wrapping materials arecommercially available as R. J. Reynolds Tobacco Company Grades 119,170, 419, 453, 454, 456, 465, 466, 490, 525, 535, 557, 652, 664, 672,676 and 680 from Schweitzer-Maudit International. The porosity of thewrapping material can vary, and frequently is between about 5 CORESTAunits and about 30,000 CORESTA units, often is between about 10 CORESTAunits and about 90 CORESTA units, and frequently is between about 8CORESTA units and about 80 CORESTA units.

To maximize aerosol and flavor delivery which otherwise may be dilutedby radial (i.e., outside) air infiltration through the overwrap, one ormore layers of non-porous cigarette paper may be used to envelop theaerosol source member (with or without the overwrap present). Examplesof suitable non-porous cigarette papers are commercially available fromKimberly-Clark Corp. as KC-63-5, P878-5, P878-16-2 and 780-63-5.Preferably, the overwrap is a material that is substantially impermeableto the vapor formed during use of the inventive article. If desired, theoverwrap can comprise a resilient paperboard material, foil-linedpaperboard, metal, polymeric materials, or the like, and this materialcan be circumscribed by a cigarette paper wrap. The overwrap maycomprise a tipping paper that circumscribes the component and optionallymay be used to attach a filter material to the aerosol source member, asotherwise described herein. In various implementations, other componentsmay exist between the aerosol generating component and the mouth end ofthe aerosol source member, wherein the mouth end may include a filter.For example, in some implementations one or any combination of thefollowing may be positioned between the aerosol generating component andthe mouth end: an air gap; phase change materials for cooling air;flavor releasing media; ion exchange fibers capable of selectivechemical adsorption; aerogel particles as filter medium; and othersuitable materials.

Tobacco materials useful in the present disclosure can vary and caninclude, for example, flue-cured tobacco, burley tobacco, Orientaltobacco or Maryland tobacco, dark tobacco, dark-fired tobacco andRustica tobaccos, as well as other rare or specialty tobaccos, or blendsthereof. Tobacco materials also can include so-called “blended” formsand processed forms, such as processed tobacco stems (e.g., cut-rolledor cut-puffed stems), volume expanded tobacco (e.g., puffed tobacco,such as dry ice expanded tobacco (DIET), preferably in cut filler form),reconstituted tobaccos (e.g., reconstituted tobaccos manufactured usingpaper-making type or cast sheet type processes). Various representativetobacco types, processed types of tobaccos, and types of tobacco blendsare set forth in U.S. Pat. No. 4,836,224 to Lawson et al.; U.S. Pat. No.4,924,888 to Perfetti et al.; U.S. Pat. No. 5,056,537 to Brown et al.;U.S. Pat. No. 5,159,942 to Brinkley et al.; U.S. Pat. No. 5,220,930 toGentry; U.S. Pat. No. 5,360,023 to Blakley et al.; U.S. Pat. No.6,701,936 to Shafer et al.; U.S. Pat. No. 7,011,096 to Li et al.; andU.S. Pat. No. 7,017,585 to Li et al.; U.S. Pat. No. 7,025,066 to Lawsonet al.; U.S. Pat. App. Pub. No. 2004-0255965 to Perfetti et al.; PCT WO02/37990 to Bereman; and Bombick et al., Fund. Appl. Toxicol., 39, p.11-17 (1997); which are incorporated herein by reference in theirentireties. Further example tobacco compositions that can be useful in asmoking device, including according to the present disclosure, aredisclosed in U.S. Pat. No. 7,726,320 to Robinson et al., which isincorporated herein by reference in its entirety.

Still further, the aerosol generating component may comprise an inertsubstrate having the inhalable substance, or a precursor thereof,integrated therein or otherwise deposited thereon. For example, a liquidcomprising the inhalable substance may be coated on or absorbed oradsorbed into the inert substrate such that, upon application of heat,the inhalable substance is released in a form that can be withdrawn fromthe inventive article through application of positive or negativepressure. In some aspects, the aerosol generating component may comprisea blend of flavorful and aromatic tobaccos in cut filler form. Inanother aspect, the aerosol generating component may comprise areconstituted tobacco material, such as described in U.S. Pat. No.4,807,809 to Pryor et al.; U.S. Pat. No. 4,889,143 to Pryor et al. andU.S. Pat. No. 5,025,814 to Raker, the disclosures of which areincorporated herein by reference in their entireties.

In some implementations, the aerosol generating component may includetobacco, a tobacco component, and/or a tobacco-derived material that hasbeen treated, manufactured, produced, and/or processed to incorporate anaerosol precursor composition (e.g., humectants such as, for example,propylene glycol, glycerin, and/or the like) and/or at least oneflavoring agent, as well as a burn retardant (e.g., diammonium phosphateand/or another salt) configured to help prevent ignition, pyrolysis,combustion, and/or scorching of the aerosol delivery component by theheat source. Various manners and methods for incorporating tobacco intosmoking articles, and particularly smoking articles that are designed soas to not purposefully burn virtually all of the tobacco within thosesmoking articles are set forth in U.S. Pat. No. 4,947,874 to Brooks etal.; U.S. Pat. No. 7,647,932 to Cantrell et al.; U.S. Pat. No. 8,079,371to Robinson et al.; U.S. Pat. No. 7,290,549 to Banerjee et al.; and U.S.Pat. App. Pub. No. 2007/0215167 to Crooks et al.; the disclosures ofwhich are incorporated herein by reference in their entireties.

In some implementations, other flame/burn retardant materials andadditives may be included within the aerosol generating component and myinclude organo-phosophorus compounds, borax, hydrated alumina, graphite,potassium tripolyphosphate, dipentaerythritol, pentaerythritol, andpolyols. Others such as nitrogenous phosphonic acid salts, mono-ammoniumphosphate, ammonium polyphosphate, ammonium bromide, ammonium borate,ethanolammonium borate, ammonium sulphamate, halogenated organiccompounds, thiourea, and antimony oxides are may also be used. In eachaspect of flame-retardant, burn-retardant, and/or scorch-retardantmaterials used in the aerosol generating component and/or othercomponents (whether alone or in combination with each other and/or othermaterials), the desirable properties are preferably provided withoutundesirable off-gassing, chemically reactive, or melting-type behavior.Additional flavorants, flavoring agents, additives, and other possibleenhancing constituents are described in U.S. patent application Ser. No.15/707,461 to Phillips et al., which is incorporated herein by referencein its entirety.

In addition to the inhalable substance (e.g., flavors, nicotine, orpharmaceuticals generally), the aerosol generating component maycomprise one or more aerosol-forming or vapor-forming materials, such asa polyhydric alcohol (e.g., glycerin, propylene glycol, or a mixturethereof) and/or water. Representative types of aerosol forming materialsare set forth in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr. et al.; andU.S. Pat. No. 5,101,839 to Jakob et al.; PCT WO 98/57556 to Biggs etal.; and Chemical and Biological Studies on New Cigarette Prototypesthat Heat Instead of Burn Tobacco, R. J. Reynolds Tobacco CompanyMonograph (1988); which are incorporated herein by reference. Apreferred aerosol forming material produces a visible aerosol upon theapplication of sufficient heat thereto, and a highly preferred aerosolforming material produces an aerosol that can be considered to be“smoke-like.” Further tobacco materials, such as a tobacco aroma oil, atobacco essence, a spray dried tobacco extract, a freeze dried tobaccoextract, tobacco dust, or the like may be combined with thevapor-forming or aerosol-forming material. It is also understood thatthe inhalable substance itself may be in a form whereby, upon heating,the inhalable substance is released as a vapor, aerosol, or combinationthereof. In other implementations, the inhalable substance may notnecessarily release in a vapor or aerosol form, but the vapor-forming oraerosol-forming material that may be combined therewith can form a vaporor aerosol upon heating and function essentially as a carrier for theinhalable substance itself. Thus, the inhalable substance may becharacterized as being coated on a substrate, as being absorbed in asubstrate, as being adsorbed onto a surface of a substrate, or as beinga natural component of the substrate (i.e., the material forming thesubstrate, such as a tobacco or a tobacco-derived material). Likewise,an aerosol-forming or vapor-forming material may be similarlycharacterized. In certain implementations, the aerosol generatingcomponent may particularly comprise a substrate with the inhalablesubstance and a separate aerosol forming material included therewith. Assuch, in use, the substrate may be heated, the aerosol forming materialmay be volatilized into a vapor form taking with it the inhalablesubstance. In a specific example, the aerosol generating component maycomprise a solid substrate with a slurry of tobacco and anaerosol-forming material and/or vapor-forming material coated thereon orabsorbed or adsorbed therein. The substrate component may be anymaterial that does not combust or otherwise degrade at the temperaturesdescribed herein that the heating member achieves to facilitate releaseof the inhalable substance. For example, a paper material may be used,including a tobacco paper (e.g., a paper-like material comprisingtobacco fibers and/or reconstituted tobacco). Thus, in variousimplementations, the aerosol generating component may be characterizedas comprising the inhalable substance, alternately as comprising theinhalable substance and a separate aerosol-former or vapor-former,alternately as comprising the inhalable substance and a substrate, oralternately as comprising the aerosol generating component, the separateaerosol-former or vapor-former, and the substrate. Thus, the substratemay contain one or both of the inhalable substance and theaerosol-former or vapor-former.

If desired, the tobacco material or the aerosol generating component maygenerally further include other components, such as sugars, glycerin,vanilla, cocoa, licorice, and other flavoring materials, such asmenthol. Example plant-derived compositions that may be used aredisclosed in U.S. Pat. App. Pub. No. 2012/0152265 to Dube et al., andU.S. Pat. No. 9,107,453 to Dube et al. The selection of such furthercomponents may vary based upon factors such as the sensorycharacteristics that are desired for the present article, and thepresent disclosure is intended to encompass any such further componentsthat may be readily apparent to those skilled in the art of tobacco andtobacco-related or tobacco-derived products. See, Gutcho, TobaccoFlavoring Substances and Methods, Noyes Data Corp. (1972) andLeffingwell et al., Tobacco Flavoring for Smoking Products (1972).

The inhalable substance and/or the separate vapor forming material maybe provided on the aerosol generating component in a variety ofconfigurations. For example, both materials may be associated with thesubstrate such that the concentration of each material along the lengthof the substrate is substantially constant (e.g., when dividing thesubstrate into a plurality of lengthwise segments, the totalconcentration of material in each individual segment can besubstantially similar, such as varying by less than 10%, less than 5%,or less than 2% by mass). In other implementations, one or both of thematerials may be present in a defined pattern. For example, the patternmay be a gradient wherein the concentration continually increases ordecreases along the length of the substrate. In this manner, the firstpuff on the article may provide an amount of the inhalable substancethat is significantly greater than or less than the amount of theinhalable substance in the last puff. The gradient may also be designedto provide uniform production of inhalable substance across all puffs.Moreover, the pattern may be such that a bolus of inhalable substance isprovided at some point along the length of the substrate (e.g.,corresponding to the first puff, the last puff, or some intermediatepuff on the article). Any variety of such patterns may be envisioned inlight of the present disclosure, and such variations are likewiseencompassed by the present disclosure. Such patterning likewise mayapply to further components as described herein (e.g., flavorants). Forexample, a bolus of a flavorant may be provided on the substrate in aposition to substantially correspond to the last puff or the last two orthree puffs on the article. The release of such flavor may signal to theconsumer that the final puff on the device is approaching or has beenachieved. Various other configurations and components that may beincluded in the aerosol generating component of the present disclosureare described in in U.S. Pat. No. 9,078,473 to Worm et al., which isincorporated herein by reference in its entirety.

In some aspects of the present disclosure, the aerosol generatingcomponent may be configured as an extruded material, as described inU.S. Pat. App. Pub. No. 2012/0042885 to Stone et al., which isincorporated herein by reference in its entirety. In still otheraspects, the aerosol generating component may be configured as anextruded structure and/or substrate that includes, or is essentiallycomprised of tobacco, tobacco-related material, glycerin, water, and/ora binder material, although certain formulations exclude the bindermaterial. In various implementations, the binder material may be anybinder material commonly used for tobacco formulations including, forexample, carboxymethyl cellulose (CMC), gum (e.g. guar gum), xanthan,pullulan, and/or an alginate. According to some aspects, the bindermaterial included in the aerosol delivery component may be configured tosubstantially maintain a structural shape and/or integrity of theaerosol delivery component. Various representative binders, binderproperties, usages of binders, and amounts of binders are set forth inU.S. Pat. No. 4,924,887 to Raker et al., which is incorporated herein byreference in its entirety.

In some implementations, the aerosol generating component may be furtherconfigured to substantially maintain its structure throughout theaerosol-generating process. That is, the aerosol generating component isconfigured to substantially maintain its shape (i.e., the aerosoldelivery component does not continually deform under an applied shearstress) throughout the aerosol-generating process. Although in someimplementations the aerosol generating component may include liquidsand/or some moisture content, in some implementations the aerosolgenerating component is configured to remain substantially solidthroughout the aerosol-generating process and substantially maintain itsstructural integrity throughout the aerosol-generating process. Exampletobacco and/or tobacco related materials suitable for a substantiallysolid aerosol delivery component are described in U.S. Pat. App. Pub.No. 2015/0157052 to Ademe et al.; U.S. Pat. App. Pub. No. 2015/0335070to Sears et al.; U.S. Pat. No. 6,204,287 to White; and U.S. Pat. No.5,060,676 to Hearn et al., which are all incorporated herein in theirentireties by reference respectively.

In yet another aspect, the aerosol generating component may include anextruded structure and/or substrate formed from marumarized and/ornon-marumarized tobacco. Marumarized tobacco is known, for example, fromU.S. Pat. No. 5,105,831 to Banerjee, et al., which is incorporated byreference herein in its entirety. Marumarized tobacco includes about 20to about 50 percent (by weight) tobacco blend in powder form, withglycerol (at about 20 to about 30 percent weight), calcium carbonate(generally at about 10 to about 60 percent by weight, often at about 40to about 60 percent by weight), along with binder agents, as describedherein, and/or flavoring agents.

In various implementations, the aerosol generating component wall may beformed substantially of a material that can include the inhalablesubstance naturally therein (e.g., tobacco paper) or may be formed ofany further material (e.g., paper) that can have the inhalable substanceand/or the vapor-former or aerosol-former entrained therein. In additionto the inhalable substance and/or the vapor-forming or aerosol-formingsubstance, the substrate wall may comprise additional components. Forexample, a vapor barrier may be included on the outer surface of theaerosol generating component wall. Preferably, the vapor barrier ispositioned on the wall surface that is adjacent (or in contact with) theheating member when the aerosol generating component is heated. Inparticular implementations, the vapor barrier may be formed of amaterial that is electrical insulating or may comprise a layer ofelectrically insulating material that can be in contact with the heatingmember. For example, a metal foil may be used as the vapor barrier, andthe foil may have an insulating monolayer—e.g., a metal oxide layer—incontact with the heating member to prevent release of vapor or aerosolinto the exterior volume of the aerosol generating component andfacilitate release of the vapor or aerosol into an annular space definedby the inner surface of the aerosol generating component wall. Any vaporbarrier material, such as a metal foil, may be used.

In further implementations, the aerosol generating component may beformed of a material that softens or changes phase (especially fromsolid to molten) at about the working temperature of the article. Forexample, the aerosol generating component may be a wax or a gel, and theinhalable substance may be entrained therein. In such implementations,it can be particularly useful to include the vapor barrier (or similarmaterial) that provides support to the aerosol generating component andsubstantially prevents the aerosol generating component from contactingthe heating member. Likewise, the aerosol generating component maycomprise a vapor barrier layer coated with an inhalable substance and/oran aerosol forming material. For example, one or more of such coatingmaterials may be in a microencapsulated form that preferably releasesits components at a temperature within one or more of the working rangesotherwise described herein. Microencapsulation technology that may beuseful in such implementations is disclosed, for example, in U.S. Pat.No. 4,464,434 to Davis.

In one implementation, the aerosol generating component may comprise atobacco component (such as, for example, a reconstituted cast tobaccosheet or tobacco beads) or a non-tobacco component (such as, forexample, herbs, paper, cellulose, etc.) with one or more of thefollowing: a binder component, a humectant component, a flavorcomponent, a moisturizer component, and a casing material. In someimplementations, the binder component may include, for example,cellulose and/or guar gum. In some implementations, the humectantcomponent may comprise glycerol, for example at approximately 15-25%,sorbitol at approximately 14.5%, and/or propylene glycol atapproximately 3-10%. In some implementations, the flavor component maycomprise, for example, acetic acid, citric acid, acetoin, lactic acid,menthol, peppermint oil, carob bin/extract, cocoa products, licoriceextract, invent sugar, and/or sucrose. In some implementations, themoisturizer component comprise, for example, water at approximately15-25%.

As discussed above, the end of the aerosol source member 104 oppositethe mouth end is sized and shaped for insertion into the receivingsleeve 116. In various implementations, the outer diameter (or otherdimension depending upon the specific cross-sectional shape of theimplementations) of the aerosol source member 104 is preferably sized tobe slightly less than the inner diameter (or other dimension) of thereceiving sleeve 116. Ideally, the difference in the respectivediameters is sufficiently small so that the aerosol source member 104fits snugly into the receiving sleeve 116, and frictional forces preventthe aerosol source member from being moved without an applied force.

As noted, in some implementations, the aerosol source member may includean overwrap. When the overwrap is present, the overall length thereofcan vary from being substantially identical to the length of the aerosolgenerating component up to about two times the length of the aerosolgenerating component. Thus, the aerosol generating component may have alength that is up to about 50%, up to about 30%, or up to about 10% lessthan the length of the overwrap. Preferably, the aerosol generatingcomponent may have a length that is at least 10%, at least 15%, or atleast 20% less than the length of the overwrap. More specifically, thedistance the overwrap extends beyond the aerosol generating componentmay be about 5%, about 10%, about 15%, about 20%, about 25%, about 30%,about 40%, about 50%, about 60%, about 70%, about 80%, about 90%, orabout 100% of the length of the aerosol generating component.

The overwrap also can function to provide particular characteristics atthe mouth end of the aerosol source member. For example, theconstruction and/or shape and/or dimension of the overwrap can functionto provide the sensation of a conventional cigarette in the mouth of auser. Moreover, as noted the overwrap may comprise a filter (e.g.,cellulose acetate or polypropylene) positioned in proximity to the mouthend of the cartridge to increase the structural integrity thereof and/orto provide filtering capacity, if desired, and/or to provide resistanceto draw.

The implementations depicted in FIGS. 1-4 describe a heating assembly inwhich, in the closed position, a series of heating members (in theseimplementations the series of heating pins 120) pass through the aerosolsource member 104. In other implementations, a series of heating membersneed not extend through the aerosol source member, but, rather, mayextend some depth into an aerosol source member. For example, FIG. 5illustrates a perspective view of a component of a heating assembly ofan aerosol delivery device, in accordance with another exampleimplementation of the present disclosure. In particular, FIG. 5 depictsa moveable jaw 212 that may be used in conjunction with a housing,electrical energy source, control component, and aerosol delivery devicesimilar to those described above. Although in various implementationsone or more of these components may differ (or may be omitted),reference is made to the descriptions above relating to thesecomponents.

Although other materials are possible, in the depicted implementation,the moveable jaw 212 may be made of a metal material (e.g., aluminum,stainless steel, metal alloys, etc.), a ceramic material (e.g., alumina,silica, mullite, silicon carbide, silicon nitride, aluminum nitride,boron nitride, etc.), a polymer material (e.g., polyimide, thermoplasticpolyimide, polybenzimidazole, polyether ether ketone, polypropylene,high density polyethylene, etc.), a composite material, and/or anycombinations thereof. As will be discussed in more detail below, themoveable jaw 212 of the depicted implementation is configured to movebetween an open position, in which the moveable jaw is spaced from astationary jaw, and a closed position, in which the moveable jaw 212 isadjacent the stationary jaw. In many aspects, the moveable jaw 212 maybe configured for use with a stationary jaw similar to the stationaryjaw described with respect to FIGS. 1-4, and thus reference is made thedescription above; however, as will be explained in more detail below,the moveable jaw 212 of the depicted implementation is configured foruse with a stationary jaw that need not include electrical connectors.

The moveable jaw 212 may be configured for use with a receiving sleevesimilar to the receiving sleeve described with respect to FIGS. 1-4, andthus reference is made the description above. As similarly describedabove, the receiving sleeve of some implementations may have asubstantially cylindrical shape configured to receive at least theheated end of the aerosol source member. In such implementations, eachof the moveable jaw 212 and the stationary jaw may have an internalshape configured to substantially surround the receiving sleeve and thusat least the heated end of the aerosol source member. In particular, aninterior surface 218 of the moveable jaw 112 and an interior surface ofthe stationary jaw together form a shape complementary of the shape ofthe receiving sleeve. In such a manner, when the moveable jaw 212 is inthe closed position, the internal surfaces come together to surround thereceiving sleeve.

The moveable jaw 212 of the depicted implementation includes a series ofindividual heating elements 220, which extend outward from the internalsurface 218 thereof. The moveable jaw 212 of the depicted implementationalso includes a pair of locating pins 222, which extend outward from theinternal surface 218 of the moveable jaw 212, although it should benoted that in some implementations there need not be any locating pins222. In the implementation described above with respect to FIGS. 1-4, aseries of heating pins are configured to electrically connect (in theclosed position) with a series of corresponding connectors located on astationary jaw to create closed heating circuits; however, in thedepicted implementation, the series of heating elements 220 compriseindividual closed resistive heating circuits each of which is configuredto heat a segment of the aerosol source member. As such, when themoveable jaw 212 is in in the closed position, the heating elements 220extend some depth into the aerosol source member. For example, in someimplementations, the heating elements 220 extend less than half-waythrough the aerosol source member. In other implementations, the heatingelements 220 extend approximately half-way through the aerosol sourcemember. In still other implementations, the heating elements 220 extendmore than half-way through the aerosol source member. It should be notedthat in some implementations, individual heating elements 220 within theseries of heating elements 220 may extend different depths into theaerosol source member.

The heating elements 220 of the depicted implementation compriseresistive heating elements and have a blade-like shape (e.g., arelatively thin and flat configuration with an angled top portion),although in other implementations the heating elements 220 may haveother shapes, such as, for example, a substantially cylindrical shapewith a heating element positioned around an external surface thereof.Resistive heating elements may be configured to produce heat when anelectrical current is directed therethrough. Such heating elements oftencomprise a metal material and are configured to produce heat as a resultof the electrical resistance associated with passing an electricalcurrent therethrough. In the depicted implementation, the heatingelements include a heating element wire and/or trace 220 a (hereinafterreferred to as a “heating trace”) that is constructed of an electricallyresistant material. Examples of electrically resistive materialsinclude, but are not limited to, titanium, silver, nickel, nichrome,stainless steel, tungsten, indium tin oxide, various metal alloys,ceramics such as silicon carbide and silicon nitride, composites, and/orany combination thereof. In various implementations, each heating trace220 a may be fixed on a main body portion 220 b via various techniquesincluding, for example, molding, printing, embedding, machining, squeezecasting, vapor deposition, etc. In various implementations, the mainbody portions 220 b may be constructed of a metal material (e.g.,aluminum, stainless steel, metal alloys, etc.). It should be noted thatin other implementations, the main body 220 b may be constructed ofanother material, including, for example, a ceramic material (e.g.,alumina, silica, mullite, silicon carbide, silicon nitride, aluminumnitride, oxides of metals such as zinc oxide, zirconium oxide, copperoxide, etc.), a polymer material (e.g., polyimide, thermoplasticpolyimide, polybenzimidazole, polyether ether ketone, polypropylene,high density polyethylene, etc.) composite materials, and/or anycombinations thereof.

As with the implementations described above with respect to FIGS. 1-4,the receiving sleeve of the depicted implementation is configured toreceive the heated end of the aerosol source member, which may includean aerosol generating component. In the open position, the moveable jaw212 is spaced from the stationary jaw, as well as the receiving sleeveand aerosol source member, and in the closed position, the moveable jaw212 is adjacent the stationary jaw, with the receiving sleeve andaerosol source member disposed in between. In various implementations,actuation between the open position and the closed position (and viceversa) may be accomplished in a variety ways, including, for example,manually (e.g., a consumer may press the jaws together), orautomatically or semi-automatically such as by using a hydraulic gasspring or other force-displacement mechanism that transfers directionalforce to the moveable jaw 212. Another example may include a lineardisplacement motor or other actuator configured to displace the moveablejaw 212 linearly between the open and closed positions. Other examplesinclude a piezo actuator, an ultrasonic ceramic actuator, a rotatingcoil system, a lead screw system, and/or any other system configured forgenerating and transferring directional and/or rotational motion to themoveable jaw 212. Regardless of the mechanism, this motion may beactivated via a pushbutton and/or via use of the device (such as, forexample, by powering the device, by drawing on the aerosol sourcemember, or by inserting an aerosol source member into the device) and/orvia the electrical resistance probe method as similarly discussed above.

FIG. 6 illustrates top and perspective views of certain components of aheating assembly of an aerosol delivery device in an open position,according to another example implementation of the present disclosure,and FIG. 7 illustrates a bottom view of the components shown in an openposition and a closed position. In particular, FIGS. 6 and 7 depicted amulti-piece moveable jaw 312 that may be used in conjunction with ahousing, electrical energy source, control component, and aerosoldelivery device similar to those described above. Although in variousimplementations one or more of these components may differ (or may beomitted), reference is made to the descriptions above relating to thesecomponents.

In various implementations, a multi-piece moveable jaw may include anynumber of sections, including, for example, as few as two sections, oras many as four or more sections. In the depicted implementation, themulti-piece moveable jaw 312 comprises three separate sections: a firstmovable jaw section 312-1, a second moveable jaw section 312-2, and athird moveable jaw section 312-3. Although other materials are possible,in the depicted implementation, the moveable jaw sections 312-1, 312-2,312-3 may be made of any of the following materials: metal materials(e.g., aluminum, stainless steel, metal alloys, etc.), ceramic materials(e.g., alumina, silica, mullite, silicon carbide, silicon nitride,aluminum nitride, etc.), polymers (e.g., polyimide, thermoplasticpolyimide, polybenzimidazole, polyether ether ketone, polypropylene,high density polyethylene, etc.) composite materials, and/or anycombinations thereof. As will be discussed in more detail below, themoveable jaw sections 312-1, 312-2, 312-3 are configured to movetogether between an open position, in which the moveable jaw sections312-1, 312-2, 312-3 are spaced from each other, and a closed position,in which the moveable jaw sections 312-1, 312-2, 312-3 are adjacent eachother. In the depicted implementation, there need not be a stationaryjaw, as the configuration of the moveable jaw sections 312-1, 312-2,312-3 in a closed position create a substantially closed form thatsurrounds the aerosol source member (and receiving sleeve, which may beincluded in some implementations).

As similarly described above, the receiving sleeve of someimplementations may have a substantially cylindrical shape configured toreceive at least the heated end of the aerosol source member. In suchimplementations, the moveable jaw sections 312-1, 312-2, 312-3 may havean internal shape configured to substantially surround the receivingsleeve and thus at least the heated end of the aerosol source member. Inparticular, the interior surfaces 318-1, 318-2, 318-3 of the moveablejaw sections 312-1, 312-2, 312-3 together form a shape complementary ofthe shape of the receiving sleeve. In such a manner, when the moveablejaw sections 312-1, 312-2, 312-3 are in the closed position, theinternal surfaces come together to surround the receiving sleeve.

Each moveable jaw section 312-1, 312-2, 312-3 of the depictedimplementation includes a series of heating elements 320-1, 320-2,312-3, which extend outward from respective internal surfaces 318-1,318-2, 318-3 thereof. In other implementations, it will be appreciatedthat additional or fewer heating elements may be included on eachmovable jaw section. For example, in one implementation, a singleheating element may be included on each of moveable jaw sections suchthat there are a total of three heating elements. Although otherimplementations may differ (referring to the top view shown in FIG. 6),the series of heating elements 320-1, 320-2, 312-3 of the depictedimplementation have a staggered configuration such that individualheating elements of the series of heating elements 20-1, 320-2, 312-3 donot align with each other, and thus overlap when the moveable jawsections 312-1, 312-2, 312-3 are in the closed position. In the depictedimplementation, each of the series of heating elements 320-1, 320-2,312-3 comprises individual closed resistive heating circuits, which areconfigured to heat a segment of the aerosol source member. As such, whenthe moveable jaw sections 312-1, 312-2, 312-3 are in in the closedposition, the heating elements 320-1, 320-2, 320-3 extend some depthinto the aerosol source member. For example, in the depictedimplementation, the heating elements 320-1, 320-2, 320-3 extend morethan half-way through the aerosol source member. However, in otherimplementations, the heating elements 320-1, 320-2, 320-3 may extendapproximately half-way through the aerosol source member, and in stillother implementations the heating elements 320-1, 320-2, 320-3 mayextend less than half-way through the aerosol source member.

The heating elements 320-1, 320-2, 320-3 of the depicted implementationcomprise resistive heating elements and have a blade-like shape,although in other implementations the heating elements 320-1, 320-2,320-3 may have other shapes. Resistive heating elements may beconfigured to produce heat when an electrical current is directedtherethrough. Such heating elements often comprise a metal material andare configured to produce heat as a result of the electrical resistanceassociated with passing an electrical current therethrough. Referring toFIG. 7, each of the heating elements 320-1, 320-2, 320-3 includes aheating element trace 320 a-1, 320 a-2, 320 a-3 that is constructed ofan electrically resistant material. Examples of electrically resistivematerials include, but are not limited to, titanium, silver, nickel,nichrome, stainless steel, indium tin oxide, various metal alloys,ceramics such as silicon carbide and silicon nitride, composites, and/orany combination thereof. In various implementations, the heating traces320 a-1, 320 a-2, and 320 a-3 may be fixed on the main body 320 b-1, 320b-2, 320 b-3 via printing, embedding, machining, squeeze casting, etc.In various implementations, the heating trace may be fixed on a mainbody 320 b-1, 320 b-2, 320 b-3 that is constructed of a metal material(e.g., aluminum, stainless steel, metal alloys, etc.). It should benoted that in other implementations, the main body 220 b may beconstructed of another material, including, for example, a ceramicmaterial (e.g., alumina, silica, mullite, silicon carbide, siliconnitride, aluminum nitride, etc.), a polymer material (e.g., polyimide,thermoplastic polyimide, polybenzimidazole, polyether ether ketone,polypropylene, high density polyethylene, etc.) composite materials,and/or any combinations thereof.

Although in other implementations there may not be a receiving sleeve,in the depicted implementation, a receiving sleeve (not shown) may beconfigured to receive the heated end of the aerosol source member. Inthe open position, the moveable jaw sections 312-1, 312-2, 312-3 arespaced from each other, as well as the receiving sleeve and aerosolsource member. In the closed position, the moveable jaw sections 312-1,312-2, 312-3 are adjacent each other, with the receiving sleeve andaerosol source member disposed in between. In various implementations,actuation between the open position and the closed position (and viceversa) may be accomplished in a variety ways, including, for example,manually (e.g., a consumer may press the jaws together), orautomatically or semi-automatically such as by using a hydraulic gasspring or other force-displacement mechanism that transfers directionalforce to the moveable jaw 312-1, 312-2, 312-3. Another example mayinclude a linear displacement motor or other actuator configured todisplace the moveable jaw sections 312-1, 312-2, 312-3 between the openand closed positions. Other examples include a piezo actuator, anultrasonic ceramic actuator, a rotating coil system, a lead screwsystem, a cam follower mechanism, a gear mechanism, a linkage, and/orany other system configured for generating and transferring directionaland/or rotational motion to the moveable jaw sections 312-1, 312-2,312-3. Regardless of the mechanism, this motion may be activated via apushbutton and/or via use of the device (such as, for example, bypowering the device, by drawing on the aerosol source member, or byinserting an aerosol source member into the device) and/or via theelectrical resistance probe method as similarly discussed above.

FIG. 8 illustrates a perspective view of an aerosol delivery device 400,in accordance with another example implementation of the presentdisclosure, and FIG. 9 illustrates a perspective exploded view of theaerosol delivery device 400. In particular, the aerosol delivery device400 of the depicted implementation includes a first housing portion 402,a second housing portion 404, a mouthpiece 406, an aerosol source member408 (that includes an aerosol generating component, an overwrap, and afilter), a heating assembly 410, and an indicator 412. The aerosoldelivery device 400 further includes an electrical energy source (notvisible, e.g., a battery, which may be rechargeable, and/or arechargeable supercapacitor), and a control component, (not visible,e.g., a microprocessor, individually or as part of a microcontroller, aprinted circuit board (PCB) that includes a microprocessor and/ormicrocontroller, etc.). As will be discussed in more detail below, theheating assembly 410 of various implementations comprises a series ofindependent and distinct heating members, wherein each heating member isconfigured to heat a segment of the aerosol source member 408.

In various implementations, one or both of the control component and theelectrical energy source may be coupled with the first housing portion402 and/or the second housing portion 404. For the sake of the currentapplication, the phrase “coupled with” when used with respect to onecomponent relative to another may encompass implementations in which onecomponent is located within another component and/or implementationswherein one component is separate but otherwise operatively connected toanother component. For example, in the depicted implementation, both thecontrol component and the electrical energy source are located withinthe first housing portion 402; however, in other implementations one orboth of the control component and the electrical energy source may belocated in different components. Further information regarding thecontrol component and the electrical energy source is provided below.

In various implementations, the first housing portion 402 and the secondhousing portion 404 may be mechanically engaged together in a variety ofways. For example, in some implementations, the first housing portion402 and the second housing portion 404 may engage via a threadedconnection. In other implementations, the first housing portion 402 andthe second housing portion 404 may engage via an interference orfriction fit. In other implementations, the first housing portion 402and the second housing portion 404 may engage via a magnetic connection.In other implementations, the first housing portion 402 and the secondhousing portion 404, may engage via a snap fit connection. In stillother implementations, the first housing portion 402 and the secondhousing portion 404 engage via a bayonet-type connection that includes amale component (e.g., a pin) and a female component (e.g., an L-shapedslot). It should be noted that in some implementations, the firsthousing portion 402 and the second housing portion 404 may comprise asingle, unitary housing portion.

Although other implementations may differ, in the depictedimplementation the aerosol source member 408 is inserted into the secondhousing portion 404 by removing the mouthpiece 406 and inserting theaerosol source member 408 so that it is positioned proximate (e.g.,over) the heating assembly 410. In the depicted implementation, there isa single series of heating elements 420 that extend from the heatingassembly frame 422 such that they are configured to be positioned on oneside of the aerosol source member 408; however, in other implementationsthere may be two or more series of heating elements 420 that areconfigured to be positioned on opposite sides of the aerosol sourcemember 408. After insertion of the aerosol source member 408, themouthpiece 406 can then be reinserted into the second housing portion404 such that the filter end of aerosol source member 404 is closest tothe mouthpiece 406. In such a manner, one or both the second housingportion 404 or the aerosol source member 408 may be keyed or otherwisemay include a stopping or locating feature to facilitate properpositioning thereof. In various implementations, the first housingportion 402, the second housing 404, and/or the mouthpiece 406 may bedetachable from each other, and thus any one or all may be replaceable.

In some implementations, the first housing portion 402 and/or the secondhousing portion 404 may also include one or more pushbuttons configuredto activate certain operations of the device 400, such as, for example,turning on the device and initiating heating of the heating assembly 410(e.g., one or more heating elements of the heating assembly). As will bediscussed in more detail below, in various implementations, the aerosolsource member 408 may comprise an aerosol generating component, which isconfigured to be located proximate the heating assembly 410, and afilter, which is configured to be located proximate the mouthpiece 406.It should be noted that while the first housing portion 402, the secondhousing portion 404, and the aerosol source member 408 of the depictedimplementation have a substantially elongate rectangular cuboid shape,in other implementations the first housing portion 402, the secondhousing portion 404, and/or the aerosol source member 408 may have anyother shape, including, for example, the shape of a conventionalcigarette or cigar.

In specific implementations, the first housing portion 402, the secondhousing portion 404, and/or the aerosol source member 408 may bereferred to as being disposable or as being reusable. For example, theelectrical energy source and/or the first housing portion 402 containingthe electrical energy source may comprise a replaceable battery or arechargeable battery, solid-state battery, thin-film solid-statebattery, rechargeable supercapacitor or the like, and thus may becombined with any type of recharging technology, including connection toa wall charger, connection to a car charger (i.e., cigarette lighterreceptacle), and connection to a computer, such as through a universalserial bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USBType-C), connection to a photovoltaic cell (sometimes referred to as asolar cell) or solar panel of solar cells, a wireless charger, such as acharger that uses inductive wireless charging (including for example,wireless charging according to the Qi wireless charging standard fromthe Wireless Power Consortium (WPC)), or a wireless radio frequency (RF)based charger. An example of an inductive wireless charging system isdescribed in U.S. Pat. App. Pub. No. 2017/0112196 to Sur et al., whichis incorporated herein by reference in its entirety. Further, in someimplementations, the aerosol source member 408 and/or the second housingportion 404 containing the aerosol source member, and/or the mouthpiece406 may comprise a single-use device. A single use component for usewith a control body is disclosed in U.S. Pat. No. 8,910,639 to Chang etal., which is incorporated herein by reference in its entirety.

In various implementations, the control component may comprise a controlcircuit (which may be connected to further components, as furtherdescribed herein) that may be connected by electrically conductive wiresto the electrical energy source. In various implementations, the controlcomponent may control when and how the heating assembly 410 (e.g., oneor more heating members of the heating assembly) receives electricalenergy to heat the aerosol generating component for release of theinhalable substance for inhalation by a consumer. Such control (e.g.,control of the stage of heating, including preheating and final heating)can relate to actuation of pressure sensitive switches or the like,which are described in greater detail hereinafter. It should be notedthat the terms “connected” or “coupled” should not be read asnecessitating direct connection without an intervening component.Rather, these terms may encompass direct connection and/or connectionvia one or more intervening components. As such, in variousimplementations these terms may be understood to mean operativelyconnected to or operatively coupled with. In various implementations,the control component of the present disclosure may comprise the controlcomponent described in U.S. patent application Ser. No. 15/976,526,filed on May 10, 2018, and titled Control Component for SegmentedHeating in an Aerosol Delivery Device, which is incorporated herein byreference in its entirety.

In various implementations, the control component may also be configuredto closely control the amount of heat provided to the aerosol generatingcomponent of the aerosol source member. While the heat needed tovolatilize the aerosol generating component in a sufficient volume toprovide a desired dosing of the inhalable substance for a single puffcan vary for each particular substance used, it can be particularlyuseful for the heating member to heat to a temperature of at least 120°C., at least 130° C., or at least 140° C. In some imlementations,preheating may occur at least 50° C., at least 75° C., at least 100° C.,or 125° C. In some implementations, in order to volatilize anappropriate amount of the aerosol generating component and thus providea desired dosing of the inhalable substance, the heating temperature maybe at least 150° C., at least 200° C., at least 250° C., at least 300°C., or at least 350° C. It can be particularly desirable, however, toavoid heating to temperatures substantially in excess of about 550° C.in order to avoid degradation and/or excessive, premature volatilizationof the aerosol generating component. Heating specifically should be at asufficiently low temperature and sufficiently short time so as to avoidsignificant combustion (preferably any combustion) of the aerosolgenerating component. The present disclosure may particularly providethe components of the present article in combinations and modes of usethat will yield the inhalable substance in desired amounts at relativelylow temperatures. As such, yielding can refer to one or both ofgeneration of the aerosol within the article and delivery out of thearticle to a consumer. In specific implementations, the heatingtemperature may be about 120° C. to about 300° C., about 130° C. toabout 290° C., about 140° C. to about 280° C., about 150° C. to about250° C., or about 160° C. to about 200° C. The duration of heating canbe controlled by a number of factors, as discussed in greater detailhereinbelow. Heating temperature and duration may depend upon thedesired volume of aerosol and ambient air that is desired to be drawnthrough the aerosol source member, as further described herein. Theduration, however, may be varied depending upon the heating rate of theheating members, as the article may be configured such that the heatingmembers are energized only until a desired temperature is reached.Alternatively, duration of heating may be correlated with the durationof a puff on the article by a consumer. Generally, the temperature andtime of heating (as well as the energizing turn of the heaters) will becontrolled by one or more components contained in the control body, asnoted above.

The amount of inhalable material released by the aerosol source membercan vary based upon the nature of the aerosol forming component.Preferably, the aerosol source member is configured with a sufficientamount of the aerosol forming component, with a sufficient amount of anyaerosol-former, and to function at a sufficient temperature for asufficient time to release a desired amount over a course of use. Theamount may be provided in a single inhalation from the aerosol sourcemember or may be divided so as to be provided through a number of puffsfrom the article over a relatively short length of time (e.g., less than30 minutes, less than 20 minutes, less than 15 minutes, less than 10minutes, or less than 5 minutes). For example, the device may providenicotine in an amount of about 0.01 mg to about 0.1 mg, about 0.05 mg toabout 1.0 mg, about 0.08 mg to about 0.5 mg, about 0.1 mg to about 0.3mg, or about 0.15 mg to about 0.25 mg per puff on the aerosol sourcemember. In other implementations, a desired amount may be characterizedin relation to the amount of wet total particulate matter deliveredbased on puff duration and volume. For example, the aerosol sourcemember may deliver at least 1.0 mg of wet total particulate matter oneach puff, for a defined number of puffs (as otherwise describedherein), when smoked under standard FTC smoking conditions of 2 second,35 ml puffs. Such testing may be carried out using any standard smokingmachine. In other implementations, the amount of total particulatematter (TPM) yielded under the same conditions on each puff may be atleast 1.5 mg, at least 1.7 mg, at least 2.0 mg, at least 2.5 mg, atleast 3.0 mg, about 1.0 mg to about 5.0 mg, about 1.5 mg to about 4.0mg, about 2.0 mg to about 4.0 mg, about 2.0 mg to about 3.0 mg, about4.0 mg to about 6.0 mg, about 6.0 mg to about 8.0 mg, or about 8.0 mg toabout 10.0 mg.

As noted, the aerosol delivery device 400 of some implementations mayinclude a pushbutton, which may be linked to the control component formanual control of the heating members. For example, in someimplementations the consumer may use the pushbutton to energize theheating assembly 410. Similar functionality tied to the pushbutton maybe achieved by other mechanical means or non-mechanical means (e.g.,magnetic or electromagnetic). Thusly, activation of the heating assembly410 may be controlled by a single pushbutton. Alternatively, multiplepushbuttons may be provided to control various actions separately. Insome implementations, one or more pushbuttons present may besubstantially flush with the casing of the first housing portion 402and/or the second housing portion 404.

Instead of (or in addition to) any pushbuttons, the aerosol deliverydevice 400 of the present disclosure may include components thatenergize the heating assembly 410 in response to the consumer's drawingon the article (i.e., puff-actuated heating). For example, the devicemay include a switch or flow sensor (not shown) in the first housingportion 402, and/or the second housing portion 404, and/or themouthpiece 406 that is sensitive either to pressure changes or air flowchanges as the consumer draws on the article (i.e., a puff-actuatedswitch). Other suitable current actuation/deactuation mechanisms mayinclude a temperature actuated on/off switch or a lip pressure actuatedswitch, or a touch sensor (e.g., capacitive touch sensor) configured tosense contact between a user (e.g., mouth or fingers of user) and one ormore surfaces of the aerosol delivery device 400. An example mechanismthat can provide such puff-actuation capability includes a Model163PC01D36 silicon sensor, manufactured by the MicroSwitch division ofHoneywell, Inc., Freeport, Ill. With such sensor, the heating assembly410 may be activated rapidly by a change in pressure when the consumerdraws on the device. In addition, flow sensing devices, such as thoseusing hot-wire anemometry principles, may be used to cause theenergizing of the heating assembly sufficiently rapidly after sensing achange in air flow. A further puff actuated switch that may be used is apressure differential switch, such as Model No. MPL-502-V, range A, fromMicro Pneumatic Logic, Inc., Ft. Lauderdale, Fla. Another suitable puffactuated mechanism is a sensitive pressure transducer (e.g., equippedwith an amplifier or gain stage) which is in turn coupled with acomparator for detecting a predetermined threshold pressure. Yet anothersuitable puff actuated mechanism is a vane which is deflected byairflow, the motion of which vane is detected by a movement sensingmeans. Yet another suitable actuation mechanism is a piezoelectricswitch. Also useful is a suitably connected Honeywell MicroSwitchMicrobridge Airflow Sensor, Part No. AWM 2100V from MicroSwitch Divisionof Honeywell, Inc., Freeport, Ill. Further examples of demand-operatedelectrical switches that may be employed in a heating circuit accordingto the present disclosure are described in U.S. Pat. No. 4,735,217 toGerth et al., which is incorporated herein by reference in its entirety.Other suitable differential switches, analog pressure sensors, flow ratesensors, or the like, will be apparent to the skilled artisan with theknowledge of the present disclosure. In some implementations, apressure-sensing tube or other passage providing fluid connectionbetween the puff actuated switch and aerosol source member may beincluded in the first housing portion 402 and/or the second housingportion 404 so that pressure changes during draw are readily identifiedby the switch. Other example puff actuation devices that may be usefulaccording to the present disclosure are disclosed in U.S. Pat. Nos.4,922,901, 4,947,874, and 4,947,874, all to Brooks et al., U.S. Pat. No.5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhaueret al., U.S. Pat. No. 7,040,314 to Nguyen et al., and U.S. Pat. No.8,205,622 to Pan, all of which are incorporated herein by reference intheir entireties. Reference also is made to the control schemesdescribed in U.S. Pat. No. 9,423,152 to Ampolini et al., which isincorporated herein by reference in its entirety.

In some implementations, when the consumer draws on the mouthpiece 406,the current actuation means may permit unrestricted or uninterruptedflow of current through the heating assembly 410 to generate heatrapidly. Because of the rapid heating, it can be useful to includecurrent regulating components to (i) regulate current flow through theheating members to control heating of the resistance element and thetemperature experienced thereby, and (ii) prevent overheating anddegradation of the aerosol generating component. In someimplementations, the current regulating circuit may be time-based.Specifically, such a circuit may include a means for permittinguninterrupted current flow through the heating members for an initialtime period during draw, and a timer means for subsequently regulatingcurrent flow until draw is completed. For example, the subsequentregulation can include the rapid on-off switching of current flow (e.g.,on the order of about every 1 to 50 milliseconds) to maintain theheating members within the desired temperature range. Further,regulation may comprise simply allowing uninterrupted current flow untilthe desired temperature is achieved then turning off the current flowcompletely. The heating members may be reactivated by the consumerinitiating another puff on the article (or manually actuating thepushbutton, depending upon the specific switch implementation employedfor activating the heater). Alternatively, the subsequent regulation caninvolve the modulation of current flow through the heating members tomaintain the heating members within a desired temperature range. In someimplementations, so as to release the desired dosing of the inhalablesubstance, the heating members may be energized for a duration of about0.2 second to about 5.0 seconds, about 0.3 second to about 4.0 seconds,about 0.4 second to about 3.0 seconds, about 0.5 second to about 2.0seconds, or about 0.6 second to about 1.5 seconds. One exampletime-based current regulating circuit can include a transistor, a timer,a comparator, and a capacitor. Suitable transistors, timers,comparators, and capacitors are commercially available and will beapparent to the skilled artisan. Example timers are those available fromNEC Electronics as C-1555C and from General Electric Intersil, Inc. asICM7555, as well as various other sizes and configurations of so-called“555 Timers”. An example comparator is available from NationalSemiconductor as LM311. Further description of such time-based currentregulating circuits is provided in U.S. Pat. No. 4,947,874 to Brooks etal., which is incorporated herein by reference in its entirety.

In some implementations, the order of energizing of the heaters may becontrolled by the control component and corresponding data may berecorded such that if a user turns off the device (without replacing theaerosol source member), the user may be able to later turn on the deviceand continue consuming the remaining portion of the aerosol sourcemember. For example, if the first two heaters have been energized andthe corresponding portions of the aerosol source member have beenconsumed by consumer, the user may turn off the device, and when theuser turns the device back on, the device will start with the thirdheater. As such, in some implementations aerosol source memberconsumption status data may be reset when an aerosol source member isremoved from the device. In some implementations, individual heaters maybe programmed to be energized for a number of puffs (e.g., one to fivepuffs, or more) before the next heater is energized. In variousimplementations, such programming may depend on the number of totalheaters, the consumable type and/or features (e.g., mass, size, glycerollevel, etc.). In light of the foregoing, it can be seen that a varietyof mechanisms can be employed to facilitate actuation/deactuation ofcurrent to the heating members. For example, the device may include atimer for regulating current flow in the article (such as during draw bya consumer). The device may further include a timer responsive switchthat enables and disables current flow to the heating members. Currentflow regulation also can comprise use of a capacitor and components forcharging and discharging the capacitor at a defined rate (e.g., a ratethat approximates a rate at which the heating member heats and cools).Current flow specifically may be regulated such that there isuninterrupted current flow through the heating members for an initialtime period during draw, but the current flow may be turned off orcycled alternately off and on after the initial time period until drawis completed. Such cycling may be controlled by a timer, as discussedabove, which can generate a preset switching cycle. In specificimplementations, the timer may generate a periodic digital wave form.The flow during the initial time period further may be regulated by useof a comparator that compares a first voltage at a first input to athreshold voltage at a threshold input and generates an output signalwhen the first voltage is equal to the threshold voltage, which enablesthe timer. Such implementations further can include components forgenerating the threshold voltage at the threshold input and componentsfor generating the threshold voltage at the first input upon passage ofthe initial time period.

Still further components can be utilized in the aerosol delivery deviceof the present disclosure. For example, U.S. Pat. No. 5,154,192 toSprinkel et al. discloses indicators for smoking articles; U.S. Pat. No.5,261,424 to Sprinkel, Jr. discloses piezoelectric sensors that can beassociated with the mouth-end of a device to detect user lip activityassociated with taking a draw and then trigger heating of a heatingdevice; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puffsensor for controlling energy flow into a heating load array in responseto pressure drop through a mouthpiece; U.S. Pat. No. 5,967,148 to Harriset al. discloses receptacles in a smoking device that include anidentifier that detects a non-uniformity in infrared transmissivity ofan inserted component and a controller that executes a detection routineas the component is inserted into the receptacle; U.S. Pat. No.6,040,560 to Fleischhauer et al. describes a defined executable powercycle with multiple differential phases; U.S. Pat. No. 5,934,289 toWatkins et al. discloses photonic-optronic components; U.S. Pat. No.5,954,979 to Counts et al. discloses means for altering draw resistancethrough a smoking device; U.S. Pat. No. 6,803,545 to Blake et al.discloses specific battery configurations for use in smoking devices;U.S. Pat. No. 7,293,565 to Griffen et al. discloses various chargingsystems for use with smoking devices; U.S. Pat. No. 8,402,976 toFernando et al. discloses computer interfacing means for smoking devicesto facilitate charging and allow computer control of the device; U.S.Pat. No. 8,689,804 to Fernando et al. discloses identification systemsfor smoking devices; and PCT Pat. App. Pub. No. WO 2010/003480 by Flickdiscloses a fluid flow sensing system indicative of a puff in an aerosolgenerating system; all of the foregoing disclosures being incorporatedherein by reference in their entireties. Another method uses anelectrical resistance change for actuating the aerosol delivery deviceand/or the heating assembly thereof. It works by using a very thin smallmetallic probe in the form of strip or wire that is installedperpendicular to the air flow inside the cartridge. The air flowgenerated by the user applies mechanical force on the probe and folds itto some extent. Due to this change in geometry that results inbending/tension in part of the probe, a change in electrical resistanceof the probe occurs, this resistance alteration is sent as apulse/information to the PCB and works as a trigger to activate theheating assembly 410.

Further examples of components related to electronic aerosol deliveryarticles and disclosing materials or components that may be used in thepresent article include U.S. Pat. No. 4,735,217 to Gerth et al.; U.S.Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No. 5,666,977 to Higginset al.; U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat. No. 6,164,287to White; U.S. Pat. No. 6,196,218 to Voges; U.S. Pat. No. 6,810,883 toFelter et al.; U.S. Pat. No. 6,854,461 to Nichols; U.S. Pat. No.7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi; U.S. Pat. No.7,896,006 to Hamano; U.S. Pat. No. 6,772,756 to Shayan; U.S. Pat. Nos.8,156,944 and 8,375,957 to Hon; U.S. Pat. No. 8,794,231 to Thorens etal.; U.S. Pat. No. 8,851,083 to Oglesby et al.; U.S. Pat. Nos. 8,915,254and 8,925,555 to Monsees et al.; U.S. Pat. No. 9,220,302 to DePiano etal.; U.S. Pat. App. Pub. Nos. 2006/0196518 and 2009/0188490 to Hon; U.S.Pat. App. Pub. No. 2010/0024834 to Oglesby et al.; U.S. Pat. App. Pub.No. 2010/0307518 to Wang; PCT Pat. App. Pub. No. WO 2010/091593 to Hon;and PCT Pat. App. Pub. No. WO 2013/089551 to Foo, each of which isincorporated herein by reference in its entirety. Further, U.S. patentapplication Ser. No. 14/881,392 to Worm et al., filed Oct. 13, 2015,discloses capsules that may be included in aerosol delivery devices andfob-shape configurations for aerosol delivery devices, and isincorporated herein by reference in its entirety. A variety of thematerials disclosed by the foregoing documents may be incorporated intothe present devices in various implementations, and all of the foregoingdisclosures are incorporated herein by reference in their entireties.

As noted above, the electrical energy source used to provide power tothe various electrical components of the device 400 may take on variousimplementations. Preferably, the electrical energy source is able todeliver sufficient energy to rapidly heat the heating members in themanner described above and power the device through use with multipleaerosol source members 408 while still fitting conveniently in thedevice 400. Examples of useful electrical energy sources includelithium-ion batteries that are preferably rechargeable (e.g., arechargeable lithium-manganese dioxide battery). In particular, lithiumpolymer batteries can be used as such batteries can provide increasedsafety. Other types of batteries—e.g., nickel-cadmium cells—may also beused. Additionally, a preferred electrical energy source is of asufficiently light weight to not detract from a desirable smokingexperience. Some examples of possible electrical energy sources aredescribed in U.S. Pat. No. 9,484,155 to Peckerar et al., and U.S. Pat.App. Pub. No. 2017/0112191 to Sur et al., filed Oct. 21, 2015, thedisclosures of which are incorporated herein by reference in theirrespective entireties.

One example of an electrical energy source is a TKI-1550 rechargeablelithium-ion battery produced by Tadiran Batteries GmbH of Germany. Inanother implementation, a useful electrical energy source may be aN50-AAA CADNICA nickel-cadmium cell produced by Sanyo Electric Company,Ltd., of Japan. In other implementations, a plurality of such batteries,for example providing 1.2-volts each, may be connected in series. Otherelectrical energy sources, such as rechargeable lithium-manganesedioxide batteries, may also be used. Any of these batteries orcombinations thereof may be used in the electrical energy source, butrechargeable batteries are preferred because of cost and disposalconsiderations associated with disposable batteries. In implementationswhere rechargeable batteries are used, the aerosol delivery device 400may further include charging contacts for interaction with correspondingcontacts in a conventional recharging unit (not shown) deriving powerfrom a standard 120-volt AC wall outlet, or other sources such as anautomobile electrical system or a separate portable power supply. Infurther implementations, the electrical energy source may also comprisea capacitor. Capacitors are capable of discharging more quickly thanbatteries and can be charged between puffs, allowing the battery todischarge into the capacitor at a lower rate than if it were used topower the heating member directly. For example, a supercapacitor—e.g.,an electric double-layer capacitor (EDLC)—may be used separate from orin combination with a battery. When used alone, the supercapacitor maybe recharged before each use of the device 400. Thus, the presentdisclosure also may include a charger component that can be attached tothe device between uses to replenish the supercapacitor. Thin filmbatteries may be used in certain implementations of the presentdisclosure.

As noted above, in various implementations, the aerosol delivery device400 may comprise one or more indicators, such as indicator 412, which inthe depicted implementation is located proximate a distal end of thefirst housing portion 402. In various implementations, the one or moreindicators may be located at any location on the first housing portion402, and/or the second housing portion 404, and/or the mouthpiece 406.In some implementations, an indicator may comprise a light (e.g., asingle or multi-color light emitting diode (LED)) that may provideindication of multiple aspects of use of the device. For example, insome implementations a series of lights may correspond to the number ofpuffs for a given aerosol source member. Specifically, the lights maysuccessively become lit with each puff such that when all lights arelit, the consumer is informed that the aerosol source member is spent.Alternatively, all lights may be lit upon the aerosol source memberbeing inserted into the housing, and a light may turn off with eachpuff, such that when all lights are off, the consumer is informed thatthe aerosol source member is spent. In other implementations, forexample, each light may correspond to a respective heating element andonce a respective heating element has reached a puff threshold (e.g.,one to five puffs or more), the light may be turned off, indicating thatpart of the aerosol source member is spent. In still otherimplementations, only a single indicator may be present, and lightingthereof may indicate that current was flowing to the heating member andthe device is actively heating. This may ensure that a consumer does notunknowingly leave the device unattended in an actively heating mode. Inalternative implementations, one or more of the indicators may be acomponent of the aerosol source member. Although the indicators aredescribed above in relation to visual indicators in an on/off method,other indices of operation also are encompassed. For example, visualindicators also may include changes in light color or intensity to showprogression of the smoking experience. Tactile indicators and audibleindicators similarly are encompassed by the present disclosure.Moreover, combinations of such indicators also may be used in a singledevice.

In various implementations, the first housing portion 402, and/or thesecond housing portion 404, and/or the mouthpiece 406 may be formed ofany material suitable for forming and maintaining an appropriateconformation, such as a tubular or rectangular shape, and for retainingtherein an aerosol source member. In some implementations, the housingmay be formed of a single wall, or multiple walls, and from a materialor multiple materials (natural or synthetic) that are heat resistant soas to retain its structural integrity—e.g., does not degrade—at least ata temperature that is the heating temperature provided by the electricalheating member, as further discussed herein. In some implementations, aheat resistant polymer may be used. In other implementations, ceramicmaterials may be used. In further implementations, an insulatingmaterial may be used so as not to unnecessarily move heat away from theaerosol source member. The housing, when formed of a single layer, mayhave a thickness that preferably is about 0.1 mm to about 2 mm, about0.2 mm to about 5.0 mm, about 0.5 mm to about 4.0 mm, about 0.5 mm toabout 3.0 mm, or about 1.0 mm to about 3.0 mm. Further example types ofcomponents and materials that may be used to provide the functionsdescribed above or be used as alternatives to the materials andcomponents noted above can be those of the types set forth in U.S. Pat.App. Pub. Nos. 2010/00186757 to Crooks et al.; 2010/00186757 to Crookset al.; and 2011/0041861 to Sebastian et al.; the disclosures of thedocuments being incorporated herein by reference in their entireties.

As shown in FIG. 9, the depicted implementation includes a heatingassembly 410 that includes a series of individual resistive heatingelements 420 that extend from a heating assembly frame 422. In variousimplementations, the control component is configured to control theindividual heating elements 420 independently and/or in any combination,with activation of the heating elements 420 being initiated using any ofthe methods described above. In the depicted implementation, each of theheating elements 420 is configured to heat a segment of the aerosolsource member 408. The heating elements 420 of the depictedimplementation comprise resistive heating elements and have asubstantially planar rectangular shape, although in otherimplementations the heating elements 420 may have other shapes.Resistive heating elements may be configured to produce heat when anelectrical current is directed therethrough. Such heating elements oftencomprise a metal material or an electrically conductive ceramic materialand are configured to produce heat as a result of the electricalresistance associated with passing an electrical current therethrough.In the depicted implementation, each of the heating elements includes aheating element wire and/or trace 420 a (hereinafter referred to as a“heating trace”) that is constructed of an electrically resistantmaterial. Examples of electrically resistive materials include, but arenot limited to, titanium, silver, nickel, nichrome, stainless steel,tungsten, indium tin oxide, various metal alloys, ceramics such assilicon carbide and silicon nitride, composites, and/or any combinationthereof. In various implementations, each heating trace 420 a may befixed on a main body portion 420 b, which in the depicted implementationmay be an extension of, or part of, the heating assembly frame 422. Invarious implementations, each heating trace 420 a may be created on acorresponding main body portion 420 b via printing, embedding,machining, squeeze casting, and other particle deposition techniques,such as chemical vapor deposition (CVD), physical vapor deposition(PVD), etc. In various implementations, the heating assembly frame 422and/or the main body portion 420 b may be constructed of a metalmaterial (e.g., aluminum, stainless steel, metal alloys, etc.); however,in other implementations, the heating assembly frame 422 and/or the mainbody 420 b may be constructed of another material, including, forexample, a ceramic material (e.g., alumina, silica, mullite, siliconcarbide, silicon nitride, aluminum nitride, boron nitride, etc.), apolymer material (e.g., polyimide, thermoplastic polyimide,polybenzimidazole, polyether ether ketone, polypropylene, high densitypolyethylene, etc.) composite materials, and/or any combinationsthereof.

FIG. 10 illustrates a perspective view of the aerosol source member 408of FIG. 9, in accordance with an example implementation of the presentdisclosure. In the depicted implementation, the aerosol source member408 includes an aerosol generating component 430, an overwrap material432, and a filter 434. As will be discussed in more detail below, whenthe aerosol source member 408 of the depicted implementation isinstalled into the second housing portion 404 of the aerosol deliverydevice 400, the filter 434 may be positioned proximate the mouthpiece406. In some implementations, the aerosol source member 408 may beinsertable and removable from the second housing portion 404 such as,for example, by removing the mouthpiece 406. In other implementations,the second housing portion 404 and the aerosol source member 408 may beinsertable and removable from the first housing portion 402.

As noted, the aerosol generating component 430 of the depictedimplementation may comprise a solid or semi-solid material that may be atobacco or tobacco-derived material or a non-tobacco material. Invarious implementations, such a material may comprise tobacco-containingbeads, tobacco shreds, tobacco strips, reconstituted tobacco material,or combinations thereof, and/or a mix of finely ground tobacco, tobaccoextract, spray dried tobacco extract, extruded tobacco, tobacco castesheet, or other tobacco form mixed with optional inorganic materials(such as calcium carbonate), optional flavors and/or binders, andaerosol forming materials, such as, for example, glycerol, to form asubstantially solid or moldable (e.g., extrudable) substrate. Gels andsuspensions may also be utilized. Some representative types of solid andsemi-solid aerosol generating component constructions and formulationsare disclosed in U.S. Pat. No. 8,424,538 to Thomas et al.; U.S. Pat. No.8,464,726 to Sebastian et al.; U.S. Pat. App. Pub. No. 2015/0083150 toConner et al.; U.S. Pat. App. Pub. No. 2015/0157052 to Ademe et al.; andU.S. Pat. App. Pub. No. 2017-0000188 to Nordskog et al., filed Jun. 30,2015, all of which are incorporated by reference herein in theirentireties.

As noted above, in various implementations, the aerosol generatingcomponent may include an aerosol generating component. The aerosolgenerating component may be any material that, when heated, releases aninhalable substance, such as a flavor-containing substance. In theimplementation depicted in the figures, the aerosol generating componentis a solid or semi-solid substrate comprising the inhalable substance.The inhalable substance specifically may be a tobacco component or atobacco-derived material (i.e., a material that is found naturally intobacco that may be isolated directly from the tobacco or syntheticallyprepared) or a non-tobacco material. For example, the aerosol generatingcomponent may comprise tobacco extracts or fractions thereof combinedwith an inert substrate. The aerosol generating component may furthercomprise unburned tobacco or a composition containing unburned tobaccothat, when heated to a temperature below its combustion temperature,releases an inhalable substance. Although less preferred, the aerosolgenerating component may comprise tobacco condensates or fractionsthereof (i.e., condensed components of the smoke produced by thecombustion of tobacco, leaving flavors and, possibly, nicotine).

In various implementations, heating of the aerosol generating component430 may result in aerosolization of an aerosol precursor compositionassociated with the aerosol generating component 430. In variousimplementations, the filter 434 of the aerosol source member 408 may beconfigured to receive the generated aerosol therethrough in response toa draw applied to the mouthpiece 406 of the aerosol delivery device 400by a user. Preferably, the elements of the aerosol generating component430 do not experience thermal decomposition (e.g., charring, scorching,or burning) to any significant degree, and the aerosolized componentsare entrained in the air that is drawn through the aerosol deliverydevice 400, including a filter (if present), and into the mouth of theuser.

In one implementation, the aerosol generating component may comprise ablend of flavorful and aromatic tobaccos in cut filler form. In anotherimplementation, the aerosol generating component may comprise areconstituted tobacco material, such as described in U.S. Pat. No.4,807,809 to Pryor et al.; U.S. Pat. No. 4,889,143 to Pryor et al. andU.S. Pat. No. 5,025,814 to Raker, the disclosures of which areincorporated herein by reference in their entireties. Additionally, areconstituted tobacco material may include a reconstituted tobacco paperfor the type of cigarettes described in Chemical and Biological Studieson New Cigarette Prototypes that Heat Instead of Burn Tobacco, R. J.Reynolds Tobacco Company Monograph (1988), the contents of which areincorporated herein by reference in its entirety. For example, areconstituted tobacco material may include a sheet-like materialcontaining tobacco and/or tobacco-related materials. As such, in someimplementations, the aerosol forming component may be formed from awound roll of a reconstituted tobacco material. In anotherimplementation, the substrate material may be formed from shreds,strips, and/or the like of a reconstituted tobacco material. In anotherimplementation, the tobacco sheet may comprise a crimped sheet ofreconstituted tobacco material. In some implementations, the substratematerial may comprise overlapping layers (e.g., a gathered web), whichmay, or may not, include heat conducting constituents. Examples ofaerosol forming components that include a series of overlapping layers(e.g., gathered webs) of an initial substrate sheet formed by thefibrous filler material, aerosol forming material, and plurality of heatconducting constituents are described in U.S. patent application Ser.No. 15/905,320, filed on Feb. 26, 2018, and titled Heat ConductingSubstrate For Electrically Heated Aerosol Delivery Device, which isincorporated herein by reference in its entirety.

In some implementations, the aerosol generating components 430 mayinclude a plurality of microcapsules, beads, granules, and/or the likehaving a tobacco-related material. For example, a representativemicrocapsule may be generally spherical in shape, and may have an outercover or shell that contains a liquid center region of a tobacco-derivedextract and/or the like. In some implementations, one or more of thesubstrate materials may include a plurality of microcapsules each formedinto a hollow cylindrical shape. In some implementations, one or more ofthe substrate materials may include a binder material configured tomaintain the structural shape and/or integrity of the plurality ofmicrocapsules formed into the hollow cylindrical shape.

Tobacco materials useful in the present disclosure can vary and caninclude, for example, flue-cured tobacco, burley tobacco, Orientaltobacco or Maryland tobacco, dark tobacco, dark-fired tobacco andRustica tobaccos, as well as other rare or specialty tobaccos, or blendsthereof. Tobacco materials also can include so-called “blended” formsand processed forms, such as processed tobacco stems (e.g., cut-rolledor cut-puffed stems), volume expanded tobacco (e.g., puffed tobacco,such as dry ice expanded tobacco (DIET), preferably in cut filler form),reconstituted tobaccos (e.g., reconstituted tobaccos manufactured usingpaper-making type or cast sheet type processes). Various representativetobacco types, processed types of tobaccos, and types of tobacco blendsare set forth in U.S. Pat. No. 4,836,224 to Lawson et al.; U.S. Pat. No.4,924,888 to Perfetti et al.; U.S. Pat. No. 5,056,537 to Brown et al.;U.S. Pat. No. 5,159,942 to Brinkley et al.; U.S. Pat. No. 5,220,930 toGentry; U.S. Pat. No. 5,360,023 to Blakley et al.; U.S. Pat. No.6,701,936 to Shafer et al.; U.S. Pat. No. 7,011,096 to Li et al.; andU.S. Pat. No. 7,017,585 to Li et al.; U.S. Pat. No. 7,025,066 to Lawsonet al.; U.S. Pat. App. Pub. No. 2004-0255965 to Perfetti et al.; PCT WO02/37990 to Bereman; and Bombick et al., Fund. Appl. Toxicol., 39, p.11-17 (1997); which are incorporated herein by reference. Furtherexample tobacco compositions that can be useful in a smoking device,including according to the present disclosure, are disclosed in U.S.Pat. No. 7,726,320 to Robinson et al., which is incorporated herein byreference in its entirety.

Still further, the aerosol generating component may comprise an inertsubstrate having the inhalable substance, or a precursor thereof,integrated therein or otherwise deposited thereon. For example, a liquidcomprising the inhalable substance may be coated on or absorbed oradsorbed into the inert substrate such that, upon application of heat,the inhalable substance is released in a form that can be withdrawn fromthe inventive article through application of positive or negativepressure. In some aspects, the aerosol generating component may comprisea blend of flavorful and aromatic tobaccos in cut filler form. Inanother aspect, the aerosol generating component may comprise areconstituted tobacco material, such as described in U.S. Pat. No.4,807,809 to Pryor et al.; U.S. Pat. No. 4,889,143 to Pryor et al. andU.S. Pat. No. 5,025,814 to Raker, the disclosures of which areincorporated herein by reference in their entireties.

In some implementations, the aerosol generating component may includetobacco, a tobacco component, tobacco-derived material, and/or anon-tobacco material, that has been treated, manufactured, produced,and/or processed to incorporate an aerosol precursor composition (e.g.,humectants such as, for example, propylene glycol, glycerin, and/or thelike) and/or at least one flavoring agent, as well as a burn retardant(e.g., diammonium phosphate and/or another salt) configured to helpprevent ignition, pyrolysis, combustion, and/or scorching of the aerosoldelivery component by the heat source. Various manners and methods forincorporating tobacco into smoking articles, and particularly smokingarticles that are designed so as to not purposefully burn virtually allof the tobacco within those smoking articles are set forth in U.S. Pat.No. 4,947,874 to Brooks et al.; U.S. Pat. No. 7,647,932 to Cantrell etal.; U.S. Pat. No. 8,079,371 to Robinson et al.; U.S. Pat. No. 7,290,549to Banerjee et al.; and U.S. Pat. App. Pub. No. 2007/0215167 to Crookset al.; the disclosures of which are incorporated herein by reference intheir entireties.

In some implementations, other flame/burn retardant materials andadditives may be included within the aerosol generating component and myinclude organo-phosophorus compounds, borax, hydrated alumina, graphite,potassium tripolyphosphate, dipentaerythritol, pentaerythritol, andpolyols. Others such as nitrogenous phosphonic acid salts, mono-ammoniumphosphate, ammonium polyphosphate, ammonium bromide, ammonium borate,ethanolammonium borate, ammonium sulphamate, halogenated organiccompounds, thiourea, and antimony oxides are may also be used. In eachaspect of flame-retardant, burn-retardant, and/or scorch-retardantmaterials used in the aerosol generating component and/or othercomponents (whether alone or in combination with each other and/or othermaterials), the desirable properties are preferably provided withoutundesirable off-gassing, chemically reactive, or melting-type behavior.Additional flavorants, flavoring agents, additives, and other possibleenhancing constituents are described in U.S. patent application Ser. No.15/707,461 to Phillips et al., which is incorporated herein by referencein its entirety.

In addition to the inhalable substance (e.g., flavors, nicotine, orpharmaceuticals generally), the aerosol generating component maycomprise one or more aerosol-forming or vapor-forming materials, such asa polyhydric alcohol (e.g., glycerin, propylene glycol, or a mixturethereof) and/or water. Representative types of aerosol forming materialsare set forth in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr. et al.; andU.S. Pat. No. 5,101,839 to Jakob et al.; PCT WO 98/57556 to Biggs etal.; and Chemical and Biological Studies on New Cigarette Prototypesthat Heat Instead of Burn Tobacco, R. J. Reynolds Tobacco CompanyMonograph (1988); which are incorporated herein by reference. Apreferred aerosol forming material produces a visible aerosol upon theapplication of sufficient heat thereto, and a highly preferred aerosolforming material produces an aerosol that can be considered to be“smoke-like.” Further tobacco materials, such as a tobacco aroma oil, atobacco essence, a spray dried tobacco extract, a freeze dried tobaccoextract, tobacco dust, or the like may be combined with thevapor-forming or aerosol-forming material. It is also understood thatthe inhalable substance itself may be in a form whereby, upon heating,the inhalable substance is released as a vapor, aerosol, or combinationthereof. In other implementations, the inhalable substance may notnecessarily release in a vapor or aerosol form, but the vapor-forming oraerosol-forming material that may be combined therewith can form a vaporor aerosol upon heating and function essentially as a carrier for theinhalable substance itself. Thus, the inhalable substance may becharacterized as being coated on a substrate, as being absorbed in asubstrate, as being adsorbed onto a surface of a substrate, or as beinga natural component of the substrate (i.e., the material forming thesubstrate, such as a tobacco or a tobacco-derived material). Likewise,an aerosol-forming or vapor-forming material may be similarlycharacterized. In certain implementations, the aerosol generatingcomponent may particularly comprise a substrate with the inhalablesubstance and a separate aerosol forming material included therewith. Assuch, in use, the substrate may be heated, the aerosol forming materialmay be volatilized into a vapor form taking with it the inhalablesubstance. In a specific example, the aerosol generating component maycomprise a solid substrate with a slurry of tobacco and anaerosol-forming material and/or vapor-forming material coated thereon orabsorbed or adsorbed therein. The substrate component may be anymaterial that does not combust or otherwise degrade at the temperaturesdescribed herein that the heating member achieves to facilitate releaseof the inhalable substance. For example, a paper material may be used,including a tobacco paper (e.g., a paper-like material comprisingtobacco fibers and/or reconstituted tobacco). Thus, in variousimplementations, the aerosol generating component may be characterizedas comprising the inhalable substance, alternately as comprising theinhalable substance and a separate aerosol-former or vapor-former,alternately as comprising the inhalable substance and a substrate, oralternately as comprising the aerosol generating component, the separateaerosol-former or vapor-former, and the substrate. Thus, the substratemay contain one or both of the inhalable substance and theaerosol-former or vapor-former.

If desired, the tobacco material or the aerosol generating component maygenerally further include other components, such as sugars, glycerin,vanilla, cocoa, licorice, and other flavoring materials, such asmenthol. Example plant-derived compositions that may be used aredisclosed in U.S. Pat. App. Pub. No. 2012/0152265 to Dube et al., andU.S. Pat. No. 9,107,453 to Dube et al. The selection of such furthercomponents may vary based upon factors such as the sensorycharacteristics that are desired for the present article, and thepresent disclosure is intended to encompass any such further componentsthat may be readily apparent to those skilled in the art of tobacco andtobacco-related or tobacco-derived products. See, Gutcho, TobaccoFlavoring Substances and Methods, Noyes Data Corp. (1972) andLeffingwell et al., Tobacco Flavoring for Smoking Products (1972).

The inhalable substance and/or the separate vapor forming material maybe provided on the aerosol generating component in a variety ofconfigurations. For example, both materials may be associated with theaerosol generating component such that the concentration of eachmaterial along the length of the aerosol generating component issubstantially constant (e.g., when dividing the substrate into aplurality of lengthwise segments, the total concentration of material ineach individual segment can be substantially similar, such as varying byless than 10%, less than 5%, or less than 2% by mass). In otherimplementations, one or both of the materials may be present in adefined pattern. For example, the pattern may be a gradient wherein theconcentration continually increases or decreases along the length of thesubstrate. In this manner, the first puff on the article may provide anamount of the inhalable substance that is significantly greater than orless than the amount of the inhalable substance in the last puff. Thegradient may also be designed to provide uniform production of inhalablesubstance across all puffs. Moreover, the pattern may be such that abolus of inhalable substance is provided at some point along the lengthof the substrate (e.g., corresponding to the first puff, the last puff,or some intermediate puff on the article). Any variety of such patternsmay be envisioned in light of the present disclosure, and suchvariations are likewise encompassed by the present disclosure. Suchpatterning likewise may apply to further components as described herein(e.g., flavorants). For example, a bolus of a flavorant may be providedon the substrate in a position to substantially correspond to the lastpuff or the last two or three puffs on the article. The release of suchflavor may signal to the consumer that the final puff on the device isapproaching or has been achieved. Various other configurations andcomponents that may be included in the aerosol generating component ofthe present disclosure are described in in U.S. Pat. No. 9,078,473 toWorm et al., which is incorporated herein by reference in its entirety.

In some aspects of the present disclosure, the aerosol generatingcomponent may be configured as an extruded material, as described inU.S. Pat. App. Pub. No. 2012/0042885 to Stone et al., which isincorporated herein by reference in its entirety. In still otheraspects, the aerosol generating component may be configured as anextruded structure and/or substrate that includes, or is essentiallycomprised of tobacco, tobacco-related material, glycerin, water, and/ora binder material, although certain formulations exclude the bindermaterial. In various implementations, the binder material may be anybinder material commonly used for tobacco formulations including, forexample, carboxymethyl cellulose (CMC), gum (e.g. guar gum), xanthan,pullulan, and/or an alginate. According to some aspects, the bindermaterial included in the aerosol delivery component may be configured tosubstantially maintain a structural shape and/or integrity of theaerosol delivery component. Various representative binders, binderproperties, usages of binders, and amounts of binders are set forth inU.S. Pat. No. 4,924,887 to Raker et al., which is incorporated herein byreference in its entirety.

In some implementations, the aerosol generating component may be furtherconfigured to substantially maintain its structure throughout theaerosol-generating process. That is, the aerosol generating component isconfigured to substantially maintain its shape (i.e., the aerosoldelivery component does not continually deform under an applied shearstress) throughout the aerosol-generating process. Although in someimplementations the aerosol generating component may include liquidsand/or some moisture content, in some implementations the aerosolgenerating component is configured to remain substantially solidthroughout the aerosol-generating process and substantially maintain itsstructural integrity throughout the aerosol-generating process. Exampletobacco and/or tobacco related materials suitable for a substantiallysolid aerosol delivery component are described in U.S. Pat. App. Pub.No. 2015/0157052 to Ademe et al.; U.S. Pat. App. Pub. No. 2015/0335070to Sears et al.; U.S. Pat. No. 6,204,287 to White; and U.S. Pat. No.5,060,676 to Hearn et al., which are all incorporated herein in theirentireties by reference respectively.

In yet another aspect, the aerosol generating component may include anextruded structure and/or substrate formed from marumarized and/ornon-marumarized tobacco. Marumarized tobacco is known, for example, fromU.S. Pat. No. 5,105,831 to Banerjee, et al., which is incorporated byreference herein in its entirety. Marumarized tobacco includes about 20to about 50 percent (by weight) tobacco blend in powder form, withglycerol (at about 20 to about 30 percent weight), calcium carbonate(generally at about 10 to about 60 percent by weight, often at about 40to about 60 percent by weight), along with binder agents, as describedherein, and/or flavoring agents.

In various implementations, the aerosol generating component wall may beformed substantially of a material that can include the inhalablesubstance naturally therein (e.g., tobacco paper) or may be formed ofany further material (e.g., paper) that can have the inhalable substanceand/or the vapor-former or aerosol-former entrained therein. In additionto the inhalable substance and/or the vapor-forming or aerosol-formingsubstance, the substrate wall may comprise additional components. Forexample, a vapor barrier may be included on the outer surface of theaerosol generating component wall. Preferably, the vapor barrier ispositioned on the wall surface that is adjacent (or in contact with) theheating member when the aerosol generating component is heated. Inparticular implementations, the vapor barrier may be formed of amaterial that is electrical insulating or may comprise a layer ofelectrically insulating material that can be in contact with the heatingmember. For example, a metal foil may be used as the vapor barrier, andthe foil may have an insulating monolayer—e.g., a metal oxide layer—incontact with the heating member to prevent release of vapor or aerosolinto the exterior volume of the aerosol generating component andfacilitate release of the vapor or aerosol into an annular space definedby the inner surface of the aerosol generating component wall. Any vaporbarrier material, such as a metal foil, may be used.

In further implementations, the aerosol generating component may beformed of a material that softens or changes phase (especially fromsolid to molten) at about the working temperature of the article. Forexample, the aerosol generating component may be a wax or a gel, and theinhalable substance may be entrained therein. In such implementations,it can be particularly useful to include the vapor barrier (or similarmaterial) that provides support to the aerosol generating component andsubstantially prevents the aerosol generating component from contactingthe heating member. Likewise, the aerosol generating component maycomprise a vapor barrier layer coated with an inhalable substance and/oran aerosol forming material. For example, one or more of such coatingmaterials may be in a microencapsulated form that preferably releasesits components at a temperature within one or more of the working rangesotherwise described herein. Microencapsulation technology that may beuseful in such implementations is disclosed, for example, in U.S. Pat.No. 4,464,434 to Davis.

In one implementation, the aerosol generating component may comprise atobacco component (such as, for example, a reconstituted cast tobaccosheet or tobacco beads) or a non-tobacco component (such as, forexample, herbs, paper, cellulose, etc.) with one or more of thefollowing: a binder component, a humectant component, a flavorcomponent, a moisturizer component, and a casing material. In someimplementations, the binder component may include, for example,cellulose and/or guar gum. In some implementations, the humectantcomponent may comprise glycerol, for example at approximately 15-25%,sorbitol at approximately 14.5%, and/or propylene glycol atapproximately 3-10%. In some implementations, the flavor component maycomprise, for example, acetic acid, citric acid, acetoin, lactic acid,menthol, peppermint oil, carob bin/extract, cocoa products, licoriceextract, invent sugar, and/or sucrose. In some implementations, themoisturizer component comprise, for example, water at approximately15-25%.

In the depicted implementation, the aerosol generating component 430, ora portion thereof, is wrapped in an overwrap material 432. In thedepicted implementation, the overwrap material comprises an aluminumlaminate; however, in other implementations the overwrap material maydiffer. In some implementations, the overwrap material may be formed ofa heat conductive material and/or any material useful for providingadditional structure and/or support for the aerosol source member. Invarious implementations, the overwrap material may comprise a materialthat resists (or promotes) transfer of heat, which may include a paperor other fibrous material, such as a cellulose material. The overwrapmaterial may also include at least one filler material imbedded ordispersed within the fibrous material. In various implementations, thefiller material may have the form of water insoluble particles.Additionally, the filler material can incorporate inorganic components.In various implementations, the overwrap may be formed of multiplelayers, such as an underlying, bulk layer, and an overlying layer, suchas a typical wrapping paper in a cigarette. Such materials may include,for example, lightweight “rag fibers” such as flax, hemp, sisal, ricestraw, and/or esparto. Further discussions relating to theconfigurations for overwrap materials that may be used with the presentdisclosure may be found in U.S. Pat. No. 9,078,473 to Worm et al., whichis incorporated herein by reference in its entirety. In additionalimplementations, the overwrap material may have or more of the followingqualities: it may be impermeable to the transfer of aerosol, it may havethe ability to withstand the elevated temperature under consideration,it may promote the transfer of heat in the radial direction from theheater to the tobacco stick material, it may resist the transfer of heatin the axial direction along the tobacco stick away from the segmentbeing heated, and/or it may have relatively low thermal mass so that itdoes not inhibit rapid temperature rises of the segment being heated. Inone implementation, the overwrap material may be a stainless steel foilthat, in some implementations, may be approximately 0.001″ thick.

As noted, in the depicted implementation the aerosol source member 408includes a filter 434. In various implementations, the filter may bemade of various materials, including, for example, a cellulose acetatematerial, a polylactic resin material, and/or a polypropylene material.In various implementations, the filter may increase the structuralintegrity to the aerosol source member, and/or provide filteringcapacity, if desired, and/or provide resistance to draw. For example, anarticle according to the disclosure can exhibit a pressure drop of about50 to about 250 mm water pressure drop at 17.5 cc/second air flow. Infurther implementations, pressure drop can be about 60 mm to about 180mm or about 70 mm to about 150 mm. Pressure drop value may be measuredusing a Filtrona Filter Test Station (CTS Series) available fromFiltrona Instruments and Automation Ltd or a Quality Test Module (QTM)available from the Cerulean Division of Molins, PLC. The length of thefilter at the mouth end of the aerosol source member can vary—e.g.,about 2 mm to about 20 mm, about 5 mm to about 20 mm, or about 10 mm toabout 15 mm. In some implementations, the filter may be separate fromthe overwrap, and in other implementations the filter may be held inposition by the overwrap.

Additional example types of overwrapping materials, wrapping materialcomponents, and treated wrapping materials that may be used in overwrapin the present disclosure are described in U.S. Pat. No. 5,105,838 toWhite et al.; U.S. Pat. No. 5,271,419 to Arzonico et al.; U.S. Pat. No.5,220,930 to Gentry; U.S. Pat. No. 6,908,874 to Woodhead et al.; U.S.Pat. No. 6,929,013 to Ashcraft et al.; U.S. Pat. No. 7,195,019 toHancock et al.; U.S. Pat. No. 7,276,120 to Holmes; U.S. Pat. No.7,275,548 to Hancock et al.; PCT WO 01/08514 to Fournier et al.; and PCTWO 03/043450 to Hajaligol et al., which are incorporated herein byreference in their entireties. Representative wrapping materials arecommercially available as R. J. Reynolds Tobacco Company Grades 119,170, 419, 453, 454, 456, 465, 466, 490, 525, 535, 557, 652, 664, 672,676 and 680 from Schweitzer-Maudit International. The porosity of thewrapping material can vary, and frequently is between about 5 CORESTAunits and about 30,000 CORESTA units, often is between about 10 CORESTAunits and about 90 CORESTA units, and frequently is between about 8CORESTA units and about 80 CORESTA units.

To maximize aerosol and flavor delivery which otherwise may be dilutedby radial (i.e., outside) air infiltration through the overwrap, one ormore layers of non-porous cigarette paper may be used to envelop theaerosol source member (with or without the overwrap present). Examplesof suitable non-porous cigarette papers are commercially available fromKimberly-Clark Corp. as KC-63-5, P878-5, P878-16-2 and 780-63-5.Preferably, the overwrap is a material that is substantially impermeableto the vapor formed during use of the inventive article. If desired, theoverwrap can comprise a resilient paperboard material, foil-linedpaperboard, metal, polymeric materials, or the like, and this materialcan be circumscribed by a cigarette paper wrap. The overwrap maycomprise a tipping paper that circumscribes the component and optionallymay be used to attach a filter material to the aerosol source member, asotherwise described herein. In various implementations, other componentsmay exist between the aerosol generating component and the mouth end ofthe aerosol source member, wherein the mouth end may include a filter.For example, in some implementations one or any combination of thefollowing may be positioned between the aerosol generating component andthe mouth end: an air gap; phase change materials for cooling air;flavor releasing media; ion exchange fibers capable of selectivechemical adsorption; aerogel particles as filter medium; and othersuitable materials.

When the overwrap material is present, the overall length thereof canvary from being substantially identical to the length of the aerosolgenerating component up to about two times the length of the aerosolgenerating component. Thus, the aerosol generating component may have alength that is up to about 50%, up to about 30%, or up to about 10% lessthan the length of the overwrap. Preferably, the aerosol generatingcomponent may have a length that is at least 10%, at least 15%, or atleast 20% less than the length of the overwrap. More specifically, thedistance the overwrap extends beyond the aerosol generating componentmay be about 5%, about 10%, about 15%, about 20%, about 25%, about 30%,about 40%, about 50%, about 60%, about 70%, about 80%, about 90%, orabout 100% of the length of the aerosol generating component.

FIG. 11 illustrates a perspective exploded view of an aerosol sourcemember 500, in accordance with an example implementation of the presentdisclosure. In particular, the aerosol delivery device 500 of thedepicted implementation includes a first housing portion 502, a secondhousing portion 504, a mouthpiece 506, an aerosol source member 508 (inthe form of a cartridge that includes a liquid or semi-liquid aerosolgenerating component), a heating assembly 510, and an indicator 512. Theaerosol delivery device 500 further includes an electrical energy source(not visible, e.g., a battery, which may be rechargeable, and/or arechargeable supercapacitor), and a control component, (not visible,e.g., a microprocessor, individually or as part of a microcontroller, aprinted circuit board (PCB) that includes a microprocessor and/ormicrocontroller, etc.). As will be discussed in more detail below, theheating assembly 510 of various implementations comprises a series ofindependent and distinct heating members, wherein each heating member isconfigured to heat a segment of the aerosol source member 508.

In various implementations, one or both of the control component and theelectrical energy source may be coupled with the first housing portion502. For the sake of the current application, the phrase “coupled with”when used with respect to one component relative to another mayencompass implementations in which one component is located withinanother component and/or implementations wherein one component isseparate but otherwise operatively connected to another component. Forexample, in the depicted implementation, both the control component andthe electrical energy source are located within the first housingportion 502; however, in other implementations one or both of thecontrol component and the electrical energy source may be located indifferent components. Further information regarding the controlcomponent and the electrical energy source is provided below.

In various implementations, the first housing portion 502 and the secondhousing portion 504 may be mechanically engaged together in a variety ofways. For example, in some implementations, the first housing portion502 and the second housing portion 504 may engage via a threadedconnection. In other implementations, the first housing portion 502 andthe second housing portion 504 may engage via an interference orfriction fit. In other implementations, the first housing portion 502and the second housing portion 504 may engage via a magnetic connection.In other implementations, the first housing portion 502 and the secondhousing portion 504, may engage via a snap fit connection. In stillother implementations, the first housing portion 502 and the secondhousing portion 504 engage via a bayonet-type connection that includes amale component (e.g., a pin) and a female component (e.g., an L-shapedslot). It should be noted that in some implementations, the firsthousing portion 502 and the second housing portion 504 may comprise asingle, unitary housing portion.

Although other implementations may differ, in the depictedimplementation the aerosol source member 508 is inserted into the secondhousing portion 504 by removing the mouthpiece 506 and inserting theaerosol source member 508 so that it is positioned proximate the heatingassembly 510. In various implementations, one or both the second housingportion 504 or the aerosol source member 508 may be keyed or may includeone or more stopping or locating features to aid in the proper placementof the aerosol source member 508. In the depicted implementation, thereis a single series of heating elements 520 that extend from the heatingassembly frame 522 such that they are configured to be positioned on oneside of the aerosol source member 508; however, in other implementationsthere may be two or more series of heating elements 520 that areconfigured to be positioned on opposite sides of the aerosol sourcemember 508. After insertion of the aerosol source member 508, themouthpiece can then be reinserted into the second housing portion 504.In various implementations, the mouthpiece may attach to the secondattachment portion in a variety of different ways, including, forexample, via a press fit attachment, a threaded attachment, a hingeattachment, a magnetic attachment, etc. In various implementations, thefirst housing portion 502, the second housing 504, and/or the mouthpiece506 may be detachable from each other, and thus any one or all may bereplaceable.

In some implementations, the first housing portion 502 and/or the secondhousing portion 504 may also include one or more pushbuttons configuredto activate certain operations of the device 500, such as, for example,turning on the device and initiating heating of the heating assembly 510(e.g., one or more heating elements of the heating assembly). As will bediscussed in more detail below, in various implementations, the aerosolsource member 508 may comprise an aerosol generating component, which isconfigured to be located proximate the heating assembly 510. It shouldbe noted that while the first housing portion 502, the second housingportion 504, and the aerosol source member 508 of the depictedimplementation have a substantially elongate rectangular cuboid shape,in other implementations the first housing portion 502, the secondhousing portion 504, and/or the aerosol source member 508 may have anyother shape, including, for example, the shape of a conventionalcigarette or cigar.

In specific implementations, the first housing portion 502, the secondhousing portion 504, and/or the aerosol source member 508 may bereferred to as being disposable or as being reusable. For example, theelectrical energy source and/or the first housing portion 502 containingthe electrical energy source may comprise a replaceable battery or arechargeable battery, solid-state battery, thin-film solid-statebattery, rechargeable supercapacitor or the like, and thus may becombined with any type of recharging technology, including connection toa wall charger, connection to a car charger (i.e., cigarette lighterreceptacle), and connection to a computer, such as through a universalserial bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USBType-C), connection to a photovoltaic cell (sometimes referred to as asolar cell) or solar panel of solar cells, a wireless charger, such as acharger that uses inductive wireless charging (including for example,wireless charging according to the Qi wireless charging standard fromthe Wireless Power Consortium (WPC)), or a wireless radio frequency (RF)based charger. An example of an inductive wireless charging system isdescribed in U.S. Pat. App. Pub. No. 2017/0112196 to Sur et al., whichis incorporated herein by reference in its entirety. Further, in someimplementations, the aerosol source member 508 and/or the second housingportion 504 containing the aerosol source member 508, and/or themouthpiece 506 may comprise a single-use device. A single use componentfor use with a control body is disclosed in U.S. Pat. No. 8,910,639 toChang et al., which is incorporated herein by reference in its entirety.

In various implementations, the control component may comprise a controlcircuit (which may be connected to further components, as furtherdescribed herein) that may be connected by electrically conductive wiresto the electrical energy source. In various implementations, the controlcomponent may control when and how the heating assembly 510 (e.g., oneor more heating members) receives electrical energy to heat the aerosolgenerating component for release of the inhalable substance forinhalation by a consumer. Such control can relate to actuation ofpressure sensitive switches or the like, which are described in greaterdetail hereinafter. It should be noted that the terms “connected” or“coupled” should not be read as necessitating direct connection withoutan intervening component. Rather, these terms may encompass directconnection and/or connection via one or more intervening components. Assuch, in various implementations these terms may be understood to meanoperatively connected to or operatively coupled with. In variousimplementations, the control component of the present disclosure maycomprise the control component described in U.S. patent application Ser.No. 15/976,526, filed on May 10, 2018, and titled Control Component forSegmented Heating in an Aerosol Delivery Device, which is incorporatedherein by reference in its entirety.

In various implementations, the control component may also be configuredto closely control the amount of heat provided to the aerosol generatingcomponent of the aerosol source member. While the heat needed tovolatilize the aerosol generating component in a sufficient volume toprovide a desired dosing of the inhalable substance for a single puffcan vary for each particular substance used, it can be particularlyuseful for the heating member to heat to a temperature of at least 120°C., at least 130° C., or at least 140° C. In some implementations, inorder to volatilize an appropriate amount of the aerosol generatingcomponent and thus provide a desired dosing of the inhalable substance,the heating temperature may be at least 150° C., at least 200° C., atleast 300° C., or at least 350° C. It can be particularly desirable,however, to avoid heating to temperatures substantially in excess ofabout 550° C. in order to avoid degradation and/or excessive, prematurevolatilization of the aerosol generating component. The presentdisclosure may particularly provide the components of the presentarticle in combinations and modes of use that will yield the inhalablesubstance in desired amounts at relatively low temperatures. As such,yielding can refer to one or both of generation of the aerosol withinthe article and delivery out of the article to a consumer. In specificimplementations, the heating temperature may be about 120° C. to about300° C., about 130° C. to about 290° C., about 140° C. to about 280° C.,about 150° C. to about 250° C., or about 160° C. to about 200° C. Theduration of heating can be controlled by a number of factors, asdiscussed in greater detail hereinbelow. Heating temperature andduration may depend upon the desired volume of aerosol and ambient airthat is desired to be drawn through the aerosol source member, asfurther described herein. The duration, however, may be varied dependingupon the heating rate of the heating members, as the article may beconfigured such that the heating members are energized only until adesired temperature is reached. Alternatively, duration of heating maybe coupled to the duration of a puff on the article by a consumer.Generally, the temperature and time of heating will be controlled by oneor more components contained in the control body, as noted above.

The amount of inhalable material released by the aerosol source membercan vary based upon the nature of the aerosol forming component.Preferably, the aerosol source member is configured with a sufficientamount of the aerosol forming component, with a sufficient amount of anyaerosol-former, and to function at a sufficient temperature for asufficient time to release a desired amount over a course of use. Theamount may be provided in a single inhalation from the aerosol sourcemember or may be divided so as to be provided through a number of puffsfrom the article over a relatively short length of time (e.g., less than30 minutes, less than 20 minutes, less than 15 minutes, less than 10minutes, or less than 5 minutes). For example, the device may providenicotine in an amount of about 0.01 mg to about 0.10 mg, about 0.05 mgto about 1.0 mg, about 0.08 mg to about 0.5 mg, about 0.1 mg to about0.3 mg, or about 0.15 mg to about 0.25 mg per puff on the aerosol sourcemember. In other implementations, a desired amount may be characterizedin relation to the amount of wet total particulate matter deliveredbased on puff duration and volume. For example, the aerosol sourcemember may deliver at least 1.0 mg of wet total particulate matter oneach puff, for a defined number of puffs (as otherwise describedherein), when smoked under standard FTC smoking conditions of 2 second,35 ml puffs. Such testing may be carried out using any standard smokingmachine. In other implementations, the amount of total particulatematter (TPM) yielded under the same conditions on each puff may be atleast 1.5 mg, at least 1.7 mg, at least 2.0 mg, at least 2.5 mg, atleast 3.0 mg, about 1.0 mg to about 5.0 mg, about 1.5 mg to about 4.0mg, about 2.0 mg to about 4.0 mg, about 2.0 mg to about 3.0 mg, about4.0 mg to about 6.0 mg, about 6.0 mg to about 8.0 mg, or about 8.0 mg toabout 10.0 mg.

As noted, the aerosol delivery device 500 of some implementations mayinclude a pushbutton, which may be linked to the control component formanual control of the heating members. For example, in someimplementations the consumer may use the pushbutton to energize theheating assembly 510. Similar functionality tied to the pushbutton maybe achieved by other mechanical means or non-mechanical means (e.g.,magnetic or electromagnetic). Thusly, activation of the heating assembly510 may be controlled by a single pushbutton. Alternatively, multiplepushbuttons may be provided to control various actions separately. Insome implementations, one or more pushbuttons present may besubstantially flush with the casing of the first housing portion 502and/or the second housing portion 504.

Instead of (or in addition to) any pushbuttons, the aerosol deliverydevice 500 of the present disclosure may include components thatenergize the heating assembly 510 in response to the consumer's drawingon the article (i.e., puff-actuated heating). For example, the devicemay include a switch or flow sensor (not shown) in the first housingportion 502, and/or the second housing portion 504, and/or themouthpiece 506 that is sensitive either to pressure changes or air flowchanges as the consumer draws on the article (i.e., a puff-actuatedswitch). Other suitable current actuation/deactuation mechanisms mayinclude a temperature actuated on/off switch or a lip pressure actuatedswitch, or a touch sensor (e.g., capacitive touch sensor) configured tosense contact between a user (e.g., mouth or fingers of user) and one ormore surfaces of the aerosol delivery device 500. An example mechanismthat can provide such puff-actuation capability includes a Model163PC01D36 silicon sensor, manufactured by the MicroSwitch division ofHoneywell, Inc., Freeport, Ill. With such sensor, the heating assembly510 may be activated rapidly by a change in pressure when the consumerdraws on the device. In addition, flow sensing devices, such as thoseusing hot-wire anemometry principles, may be used to cause theenergizing of the heating assembly sufficiently rapidly after sensing achange in air flow. A further puff actuated switch that may be used is apressure differential switch, such as Model No. MPL-502-V, range A, fromMicro Pneumatic Logic, Inc., Ft. Lauderdale, Fla. Another suitable puffactuated mechanism is a sensitive pressure transducer (e.g., equippedwith an amplifier or gain stage) which is in turn coupled with acomparator for detecting a predetermined threshold pressure. Yet anothersuitable puff actuated mechanism is a vane which is deflected byairflow, the motion of which vane is detected by a movement sensingmeans. Yet another suitable actuation mechanism is a piezoelectricswitch. Also useful is a suitably connected Honeywell MicroSwitchMicrobridge Airflow Sensor, Part No. AWM 2100V from MicroSwitch Divisionof Honeywell, Inc., Freeport, Ill. Further examples of demand-operatedelectrical switches that may be employed in a heating circuit accordingto the present disclosure are described in U.S. Pat. No. 4,735,217 toGerth et al., which is incorporated herein by reference in its entirety.Other suitable differential switches, analog pressure sensors, flow ratesensors, or the like, will be apparent to the skilled artisan with theknowledge of the present disclosure. In some implementations, apressure-sensing tube or other passage providing fluid connectionbetween the puff actuated switch and aerosol source member may beincluded in the first housing portion 502 and/or the second housingportion 504 so that pressure changes during draw are readily identifiedby the switch. Other example puff actuation devices that may be usefulaccording to the present disclosure are disclosed in U.S. Pat. Nos.4,922,901, 4,947,874, and 4,947,874, all to Brooks et al., U.S. Pat. No.5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhaueret al., U.S. Pat. No. 7,040,314 to Nguyen et al., and U.S. Pat. No.8,205,622 to Pan, all of which are incorporated herein by reference intheir entireties. Reference also is made to the control schemesdescribed in U.S. Pat. No. 9,423,152 to Ampolini et al., which isincorporated herein by reference in its entirety.

In some implementations, when the consumer draws on the mouthpiece 506,the current actuation means may permit unrestricted or uninterruptedflow of current through the heating assembly 510 to generate heatrapidly. Because of the rapid heating, it can be useful to includecurrent regulating components to (i) regulate current flow through theheating members to control heating of the resistance element and thetemperature experienced thereby, and (ii) prevent overheating anddegradation of the aerosol generating component. In someimplementations, the current regulating circuit may be time-based.Specifically, such a circuit may include a means for permittinguninterrupted current flow through the heating members for an initialtime period during draw, and a timer means for subsequently regulatingcurrent flow until draw is completed. For example, the subsequentregulation can include the rapid on-off switching of current flow (e.g.,on the order of about every 1 to 50 milliseconds) to maintain theheating members within the desired temperature range. Further,regulation may comprise simply allowing uninterrupted current flow untilthe desired temperature is achieved then turning off the current flowcompletely. The heating members may be reactivated by the consumerinitiating another puff on the article (or manually actuating thepushbutton, depending upon the specific switch implementation employedfor activating the heater). Alternatively, the subsequent regulation caninvolve the modulation of current flow through the heating members tomaintain the heating members within a desired temperature range. In someimplementations, so as to release the desired dosing of the inhalablesubstance, the heating members may be energized for a duration of about0.2 second to about 5.0 seconds, about 0.3 second to about 4.0 seconds,about 0.4 second to about 3.0 seconds, about 0.5 second to about 2.0seconds, or about 0.6 second to about 1.5 seconds. One exampletime-based current regulating circuit can include a transistor, a timer,a comparator, and a capacitor. Suitable transistors, timers,comparators, and capacitors are commercially available and will beapparent to the skilled artisan. Example timers are those available fromNEC Electronics as C-1555C and from General Electric Intersil, Inc. asICM7555, as well as various other sizes and configurations of so-called“555 Timers”. An example comparator is available from NationalSemiconductor as LM311. Further description of such time-based currentregulating circuits is provided in U.S. Pat. No. 4,947,874 to Brooks etal., which is incorporated herein by reference in its entirety.

In light of the foregoing, it can be seen that a variety of mechanismscan be employed to facilitate actuation/deactuation of current to theheating members. For example, the device may include a timer forregulating current flow in the article (such as during draw by aconsumer). The device may further include a timer responsive switch thatenables and disables current flow to the heating members. Current flowregulation also can comprise use of a capacitor and components forcharging and discharging the capacitor at a defined rate (e.g., a ratethat approximates a rate at which the heating member heats and cools).Current flow specifically may be regulated such that there isuninterrupted current flow through the heating members for an initialtime period during draw, but the current flow may be turned off orcycled alternately off and on after the initial time period until drawis completed. Such cycling may be controlled by a timer, as discussedabove, which can generate a preset switching cycle. In specificimplementations, the timer may generate a periodic digital wave form.The flow during the initial time period further may be regulated by useof a comparator that compares a first voltage at a first input to athreshold voltage at a threshold input and generates an output signalwhen the first voltage is equal to the threshold voltage, which enablesthe timer. Such implementations further can include components forgenerating the threshold voltage at the threshold input and componentsfor generating the threshold voltage at the first input upon passage ofthe initial time period.

Still further components can be utilized in the aerosol delivery deviceof the present disclosure. For example, U.S. Pat. No. 5,154,192 toSprinkel et al. discloses indicators for smoking articles; U.S. Pat. No.5,261,424 to Sprinkel, Jr. discloses piezoelectric sensors that can beassociated with the mouth-end of a device to detect user lip activityassociated with taking a draw and then trigger heating of a heatingdevice; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puffsensor for controlling energy flow into a heating load array in responseto pressure drop through a mouthpiece; U.S. Pat. No. 5,967,148 to Harriset al. discloses receptacles in a smoking device that include anidentifier that detects a non-uniformity in infrared transmissivity ofan inserted component and a controller that executes a detection routineas the component is inserted into the receptacle; U.S. Pat. No.6,040,560 to Fleischhauer et al. describes a defined executable powercycle with multiple differential phases; U.S. Pat. No. 5,934,289 toWatkins et al. discloses photonic-optronic components; U.S. Pat. No.5,954,979 to Counts et al. discloses means for altering draw resistancethrough a smoking device; U.S. Pat. No. 6,803,545 to Blake et al.discloses specific battery configurations for use in smoking devices;U.S. Pat. No. 7,293,565 to Griffen et al. discloses various chargingsystems for use with smoking devices; U.S. Pat. No. 8,402,976 toFernando et al. discloses computer interfacing means for smoking devicesto facilitate charging and allow computer control of the device; U.S.Pat. No. 8,689,804 to Fernando et al. discloses identification systemsfor smoking devices; and PCT Pat. App. Pub. No. WO 2010/003480 by Flickdiscloses a fluid flow sensing system indicative of a puff in an aerosolgenerating system; all of the foregoing disclosures being incorporatedherein by reference in their entireties. Another method uses anelectrical resistance change for actuating the aerosol delivery deviceand/or the heating assembly thereof. It works by using a very thin smallmetallic probe in the form of strip or wire that is installedperpendicular to the air flow inside the cartridge. The air flowgenerated by the user applies mechanical force on the probe and folds itto some extent. Due to this change in geometry that results inbending/tension in part of the probe, a change in electrical resistanceof the probe occurs, this resistance alteration is sent as apulse/information to the PCB and works as a trigger to activate theheating assembly 510.

Further examples of components related to electronic aerosol deliveryarticles and disclosing materials or components that may be used in thepresent article include U.S. Pat. No. 4,735,217 to Gerth et al.; U.S.Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No. 5,666,977 to Higginset al.; U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat. No. 6,164,287to White; U.S. Pat. No. 6,196,218 to Voges; U.S. Pat. No. 6,810,883 toFelter et al.; U.S. Pat. No. 6,854,461 to Nichols; U.S. Pat. No.7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi; U.S. Pat. No.7,896,006 to Hamano; U.S. Pat. No. 6,772,756 to Shayan; U.S. Pat. Nos.8,156,944 and 8,375,957 to Hon; U.S. Pat. No. 8,794,231 to Thorens etal.; U.S. Pat. No. 8,851,083 to Oglesby et al.; U.S. Pat. Nos. 8,915,254and 8,925,555 to Monsees et al.; U.S. Pat. No. 9,220,302 to DePiano etal.; U.S. Pat. App. Pub. Nos. 2006/0196518 and 2009/0188490 to Hon; U.S.Pat. App. Pub. No. 2010/0024834 to Oglesby et al.; U.S. Pat. App. Pub.No. 2010/0307518 to Wang; PCT Pat. App. Pub. No. WO 2010/091593 to Hon;and PCT Pat. App. Pub. No. WO 2013/089551 to Foo, each of which isincorporated herein by reference in its entirety. Further, U.S. patentapplication Ser. No. 14/881,392 to Worm et al., filed Oct. 13, 2015,discloses capsules that may be included in aerosol delivery devices andfob-shape configurations for aerosol delivery devices, and isincorporated herein by reference in its entirety. A variety of thematerials disclosed by the foregoing documents may be incorporated intothe present devices in various implementations, and all of the foregoingdisclosures are incorporated herein by reference in their entireties.

As noted above, the electrical energy source used to provide power tothe various electrical components of the device 500 may take on variousimplementations. Preferably, the electrical energy source is able todeliver sufficient energy to rapidly heat the heating members in themanner described above and power the device through use with multipleaerosol source members 508 while still fitting conveniently in thedevice 500. Examples of useful electrical energy sources includelithium-ion batteries that are preferably rechargeable (e.g., arechargeable lithium-manganese dioxide battery). In particular, lithiumpolymer batteries can be used as such batteries can provide increasedsafety. Other types of batteries—e.g., nickel-cadmium cells—may also beused. Additionally, a preferred electrical energy source is of asufficiently light weight to not detract from a desirable smokingexperience. Some examples of possible electrical energy sources aredescribed in U.S. Pat. No. 9,484,155 to Peckerar et al., and U.S. Pat.App. Pub. No. 2017/0112191 to Sur et al., filed Oct. 21, 2015, thedisclosures of which are incorporated herein by reference in theirrespective entireties.

One example of an electrical energy source is a TKI-1550 rechargeablelithium-ion battery produced by Tadiran Batteries GmbH of Germany. Inanother implementation, a useful electrical energy source may be aN50-AAA CADNICA nickel-cadmium cell produced by Sanyo Electric Company,Ltd., of Japan. In other implementations, a plurality of such batteries,for example providing 1.2-volts each, may be connected in series. Otherelectrical energy sources, such as rechargeable lithium-manganesedioxide batteries, may also be used. Any of these batteries orcombinations thereof may be used in the electrical energy source, butrechargeable batteries are preferred because of cost and disposalconsiderations associated with disposable batteries. In implementationswhere rechargeable batteries are used, the aerosol delivery device 500may further include charging contacts for interaction with correspondingcontacts in a conventional recharging unit (not shown) deriving powerfrom a standard 120-volt AC wall outlet, or other sources such as anautomobile electrical system or a separate portable power supply. Infurther implementations, the electrical energy source may also comprisea capacitor. Capacitors are capable of discharging more quickly thanbatteries and can be charged between puffs, allowing the battery todischarge into the capacitor at a lower rate than if it were used topower the heating member directly. For example, a supercapacitor—e.g.,an electric double-layer capacitor (EDLC)—may be used separate from orin combination with a battery. When used alone, the supercapacitor maybe recharged before each use of the device 500. Thus, the presentdisclosure also may include a charger component that can be attached tothe device between uses to replenish the supercapacitor. Thin filmbatteries may be used in certain implementations of the presentdisclosure.

As noted above, in various implementations, the aerosol delivery device500 may comprise one or more indicators, such as indicator 512, which inthe depicted implementation is located proximate a distal end of thefirst housing portion 502. In various implementations, the one or moreindicators may be located at any location on the first housing portion502, and/or the second housing portion 504, and/or the mouthpiece 506.In some implementations, an indicator may comprise a light (e.g., asingle or multi-color light emitting diode (LED)) that may provideindication of multiple aspects of use of the device. For example, insome implementations a series of lights may correspond to the number ofpuffs for a given aerosol source member. Specifically, the lights maysuccessively become lit with each puff such that when all lights arelit, the consumer is informed that the aerosol source member is spent.Alternatively, all lights may be lit upon the aerosol source memberbeing inserted into the housing, and a light may turn off with eachpuff, such that when all lights are off, the consumer is informed thatthe aerosol source member is spent. In still other implementations, onlya single indicator may be present, and lighting thereof may indicatethat current was flowing to the heating member and the device isactively heating. This may ensure that a consumer does not unknowinglyleave the device unattended in an actively heating mode. In alternativeimplementations, one or more of the indicators may be a component of theaerosol source member. Although the indicators are described above inrelation to visual indicators in an on/off method, other indices ofoperation also are encompassed. For example, visual indicators also mayinclude changes in light color or intensity to show progression of thesmoking experience. Tactile indicators and audible indicators similarlyare encompassed by the present disclosure. Moreover, combinations ofsuch indicators also may be used in a single device.

In various implementations, the first housing portion 502, and/or thesecond housing portion 504, and/or the mouthpiece 506 may be formed ofany material suitable for forming and maintaining an appropriateconformation, such as a tubular or rectangular shape, and for retainingtherein an aerosol source member. In some implementations, the housingmay be formed of a single wall, or multiple walls, and from a materialor multiple materials (natural or synthetic) that are heat resistant soas to retain its structural integrity—e.g., does not degrade—at least ata temperature that is the heating temperature provided by the electricalheating member, as further discussed herein. In some implementations, aheat resistant polymer may be used. In other implementations, ceramicmaterials may be used. In further implementations, an insulatingmaterial may be used so as not to unnecessarily move heat away from theaerosol source member. The housing, when formed of a single layer, mayhave a thickness that preferably is about 0.2 mm to about 5.0 mm, about0.5 mm to about 4.0 mm, about 0.5 mm to about 3.0 mm, or about 1.0 mm toabout 3.0 mm. Further example types of components and materials that maybe used to provide the functions described above or be used asalternatives to the materials and components noted above can be those ofthe types set forth in U.S. Pat. App. Pub. Nos. 2010/00186757 to Crookset al.; 2010/00186757 to Crooks et al.; and 2011/0041861 to Sebastian etal.; the disclosures of the documents being incorporated herein byreference in their entireties.

As shown in FIG. 11, the depicted implementation includes a heatingassembly 510 that includes a series of individual resistive heatingelements 520 that extend from a heating assembly frame 522. In thedepicted implementation, there are six individual heating elements 520;however, in other implementations there may be any number of heatingelements, including, for example, as few as one, or more than six, suchas, for example, sixteen heating elements. In various implementations,the control component is configured to control the individual heatingelements 520 independently and/or in any combination, with activation ofthe heating elements 520 being initiated using any of the methodsdescribed above. In the depicted implementation, each of the heatingelements 520 is configured to heat a segment of the aerosol sourcemember 508. The heating elements 520 of the depicted implementationcomprise resistive heating elements and have a substantially planarrectangular shape, although in other implementations the heatingelements 520 may have other shapes. Resistive heating elements may beconfigured to produce heat when an electrical current is directedtherethrough. Such heating elements often comprise a metal material andare configured to produce heat as a result of the electrical resistanceassociated with passing an electrical current therethrough. In thedepicted implementation, each of the heating elements includes a heatingelement wire and/or trace 520 a (hereinafter referred to as a “heatingtrace”) that is constructed of an electrically resistant material.Examples of electrically resistive materials include, but are notlimited to, titanium, silver, nickel, nichrome, stainless steel, variousmetal alloys, ceramics such as silicon carbide and silicon nitride,composites, and/or any combination thereof. In various implementations,each heating trace 520 a may be fixed on a main body portion 520 b,which in the depicted implementation may be an extension of, or part of,the heating assembly frame 522. In various implementations, each heatingtrace 520 a may be created on a corresponding main body portion 520 bvia printing, embedding, machining, squeeze casting, etc. In variousimplementations, the heating assembly frame 522 and/or the main bodyportion 520 b may be constructed of a metal material (e.g., aluminum,stainless steel, metal alloys, etc.); however, in other implementations,the heating assembly frame 522 and/or the main body 520 b may beconstructed of another material, including, for example, a ceramicmaterial (e.g., alumina, silica, mullite, silicon carbide, siliconnitride, aluminum nitride, etc.), a polymer material (e.g., polyimide,thermoplastic polyimide, polybenzimidazole, polyether ether ketone,polypropylene, high density polyethylene, etc.) composite materials,and/or any combinations thereof.

FIG. 12 illustrates a perspective view of an aerosol source member 508in the form of a reservoir cartridge, in accordance with an exampleimplementation of the present disclosure. In various implementations theaerosol source member 508 includes a reservoir housing 540, a reservoir542, and a series of atomizer chambers 544, each of which includes aliquid transport element 546. As will be discussed in more detail below,the series of atomizer chambers 544 are configured to substantiallyalign with the series of heating elements 520 of the heating assembly510. In various implementations, the reservoir housing 540 may beconstructed of one or more of a variety of materials, including, forexample, a metal material, a ceramic material, a glass material, and/ora plastic material, such as, for example, an acrylic material (e.g.,polymethlamethacrylate). In some implementations, the reservoir housing540 may comprise a translucent or transparent material, such that a usermay view the quantity of the aerosol generating component remainingtherein. In the depicted implementation, the reservoir housing 540 isconstructed of polypropelene or Tritan™, although in otherimplementations, other materials are possible

In various implementations, the reservoir 542 may hold an aerosolgenerating component, which may be in the form of a liquid orsemi-liquid aerosol precursor composition. Some representative types ofaerosol precursor components and formulations are also set forth andcharacterized in U.S. Pat. No. 7,726,320 to Robinson et al., U.S. Pat.No. 8,881,737 to Collett et al., and U.S. Pat. No. 9,254,002 to Chong etal.; and U.S. Pat. Pub. Nos. 2013/0008457 to Zheng et al.; 2015/0020823to Lipowicz et al.; and 2015/0020830 to Koller, as well as WO2014/182736 to Bowen et al, the disclosures of which are incorporatedherein by reference in their entireties. Other aerosol precursors thatmay be employed include the aerosol precursors that have beenincorporated in VUSE® products by R. J. Reynolds Vapor Company, the BLU′products by Fontem Ventures B.V., the MISTIC MENTHOL product by MisticEcigs, MARK TEN products by Nu Mark LLC, the JUUL product by Juul Labs,Inc., and VYPE products by British American Tobacco. Also desirable arethe so-called “smoke juices” for electronic cigarettes that have beenavailable from Johnson Creek Enterprises LLC. Still further exampleaerosol precursor compositions are sold under the brand names BLACKNOTE, COSMIC FOG, THE MILKMAN E-LIQUID, FIVE PAWNS, THE VAPOR CHEF, VAPEWILD, BOOSTED, THE STEAM FACTORY, MECH SAUCE, CASEY JONES MAINLINERESERVE, MITTEN VAPORS, DR. CRIMMY'S V-LIQUID, SMILEY E LIQUID, BEANTOWNVAPOR, CUTTWOOD, CYCLOPS VAPOR, SICBOY, GOOD LIFE VAPOR, TELEOS, PINUPVAPORS, SPACE JAM, MT. BAKER VAPOR, and JIMMY THE JUICE MAN.Implementations of effervescent materials can be used with the aerosolprecursor composition, and are described, by way of example, in U.S.Pat. App. Pub. No. 2012/0055494 to Hunt et al., which is incorporatedherein by reference in its entirety. Further, the use of effervescentmaterials is described, for example, in U.S. Pat. No. 4,639,368 to Niaziet al.; U.S. Pat. No. 5,178,878 to Wehling et al.; U.S. Pat. No.5,223,264 to Wehling et al.; U.S. Pat. No. 6,974,590 to Pather et al.;U.S. Pat. No. 7,381,667 to Bergquist et al.; U.S. Pat. No. 8,424,541 toCrawford et al; U.S. Pat. No. 8,627,828 to Strickland et al.; and U.S.Pat. No. 9,307,787 to Sun et al.; as well as U.S. Pat. App. Pub. No.2010/0018539 to Brinkley et al. and PCT WO 97/06786 to Johnson et al.,all of which are incorporated by reference herein in their entireties.Additional description with respect to implementations of aerosolprecursor compositions, including description of tobacco or componentsderived from tobacco included therein, is provided in U.S. patentapplication Ser. Nos. 15/216,582 and 15/216,590, each filed Jul. 21,2016 and each to Davis et al., which are incorporated herein byreference in their entireties.

The reservoir housing 540 may include an aerosol channel 548 thatextends from one end of the reservoir housing 540, to the other end ofthe reservoir housing 540. In particular, in some implementations theaerosol channel 548 extends from a distal end of the reservoir housing540 to an end of the aerosol housing 540 that is proximate themouthpiece 506 when the aerosol source member 508 is inserted into thesecond housing portion 504. In various implementations, the aerosolchannel 548 may comprise a groove or slot in the reservoir housing 540that crosses over each of the atomizer chambers 544. In such a manner,when a user draws on the aerosol delivery device 500, the drawn airpasses over the atomizer channels 544 and may pick up any aerosol thatis generated in one or more of the atomizer chambers 544.

In the depicted implementation, the aerosol source member 508 includessix atomizer chambers 544 (and thus six liquid transport elements 546).In various implementations, the liquid transport elements 546 maycomprise porous monoliths. For example, in the depicted implementation,the liquid transport elements 546 may comprise a ceramic material suchthat aerosol precursor composition delivered to the liquid transportelements 546 may be absorbed therein for aerosolization. In otherimplementations, the liquid transport elements may comprise othermaterials, including, for example cotton, silica, cellulose, and otherfibrous materials. Although in various implementations the size andshape of the atomizer chambers may vary, in the depicted implementationthe atomizer chambers 544 have a substantially half-cylinder shape,wherein each respective liquid transport element 546 extends from oneend of the atomizer chamber 544 to the other end in an orientationsubstantially perpendicular and slightly below the aerosol channel 548.In particular, the ends of each liquid transport element 546 extendthrough the reservoir housing 540 such that the liquid transportelements 546 are in fluid contact with the aerosol precursor compositioncontained in the reservoir 542 such that the aerosol precursorcomposition flows (e.g., via capillary action) into the liquid transportelements 546.

An electrical connection between the control component and the heatingassembly 510 allows the control component to direct electrical currentto the heating assembly 510, such as upon actuation by the user (e.g.,via a button) and/or when a puff on the aerosol delivery device isdetected. A noted above, the aerosol delivery device 500 of the depictedimplementation includes a mouthpiece 506. When a user draws on themouthpiece 506, air 550 may be directed through one or more air intakesin the device 500 from the environment and into the distal end of theaerosol channel 548. In some implementations, the air 550 may enter thedevice 500 through one or more openings in the first housing portion 502and/or the second housing portion 504. In some implementations, the air550 may additionally or alternatively enter through an opening betweenthe first housing portion 502 and the second housing portion 504. Otherpossible entry openings are described in U.S. Pat. No. 9,220,302 toDePiano et al., which is incorporated herein by reference in itsentirety.

In some implementations, a sensor in the aerosol delivery device 500(e.g., the flow sensor) may sense the puff. When the puff is sensed, thecontrol component may direct current to one or more of the heatingelements 520. Accordingly, one or more of the heating elements 520 mayvaporize the aerosol precursor composition contained in the one or moreliquid transport elements 546 located proximate the activated heatingelements 520. As the air 550 enters the atomizer chambers 544, ittravels past (and/or around) the liquid transport element 546. At suchpoint, if the respective heating element 520 is active, the air 550mixes with the vaporized aerosol precursor composition and becomes theaerosol 552.

The air drawn into the aerosol channel 548 may be drawn past each of theatomizer chambers 544, such that the air 550 exits through the oppositeend of the aerosol channel 548 and through the mouthpiece 506 of thedevice 500. As illustrated, for example, if only the third heatingelement 520 is activated, the drawn air 550 will be mixed with theaerosol formed in the third atomizer chamber 544. As such, for example,if multiple heating elements 520 are activated, the air 550 will pick upaerosol from the multiple atomizer chambers 544.

In some implementations, at least a portion of the reservoir 542 maycomprise a plurality of layers of nonwoven fibers. Thus, liquidcomponents, for example, can be sorptively retained in the reservoir542. In various implementations, the reservoir 542 is in fluidconnection with the series of atomizer chambers 544. Thus, each liquidtransport element 546 may be configured to transport liquid from thereservoir 542 proximate a corresponding heating element 520 of theplurality of heating elements 520 via capillary action or other liquidtransport mechanism.

In the depicted implementation, the reservoir 542 comprises a singlereservoir compartment wherein all of the liquid transport elements 546are in contact with the same liquid composition; however, in otherimplementations, there may be two or more separate reservoircompartments, each of which may encompass one or more of the atomizerchambers. For example, in some implementations, the reservoir 542 mayinclude two or more separate reservoir compartments that are sealinglyindependent from each other. In such a manner, for example, someatomizer chambers may be separate from each other such that some of theliquid transport elements 546 are not in contact with the same liquidcomposition. For example, in some implementations where there are sixatomizer chambers, there may be two, three, four, five, or six separatereservoir chambers, each of which may contain a different liquidcomposition. As an example, one or more of the separate reservoircompartments may include different aerosol precursor compositions and/ordifferent flavorants such that a user may be able to choose between theone or more aerosol precursor compositions and/or flavorants as desired.In other implementations, separate sub-reservoirs containing differentsubstances may be heated to contribute to or add to a vapor produced bythe device. For example, one sub-reservoir may contain anicotine-containing liquid and another sub-reservoir may contain aflavorant (which, for example, may be selectable from multiplesub-reservoirs containing flavorants), the nicotine-containing liquidand the flavorant being added to the vapor produced by the device. Inanother example, two sub-reservoirs may be simultaneously heated tocreate a binary reaction in the produced vapor. For example, asub-reservoir containing an acidic liquid (such as, for example, alactic acid) may be heated and combined with a sub-reservoir containinga nicotine-liquid to form a nicotine salt in the vapor. Because thenumber of possible separate heating elements and/or reservoircompartments may vary, in some implementations a user may select among anearly infinite number of combinations of aerosol precursor compositionsand/or aerosol precursor compositions flavorants.

As used herein, reference to a “flavorant” refers to compounds orcomponents that can be aerosolized and delivered to a user and whichimpart a sensory experience in terms of taste and/or aroma. Exampleflavorants include, but are not limited to, vanillin, ethyl vanillin,cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach andcitrus flavors, including lime and lemon), maple, menthol, mint,peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom,ginger, honey, anise, sage, rosemary, hibiscus, rose hip, yerba mate,guayusa, honeybush, rooibos, yerba santa, bacopa monniera, gingkobiloba, withania somnifera, cinnamon, sandalwood, jasmine, cascarilla,cocoa, licorice, and flavorings and flavor packages of the type andcharacter traditionally used for the flavoring of cigarette, cigar, andpipe tobaccos. Syrups, such as high fructose corn syrup, also can beemployed. Example plant-derived compositions that may be suitable aredisclosed in U.S. Pat. No. 9,107,453 and U.S. Pat. App. Pub. No.2012/0152265 both to Dube et al., the disclosures of which areincorporated herein by reference in their entireties. The selection ofsuch further components are variable based upon factors such as thesensory characteristics that are desired for the smoking article, andthe present disclosure is intended to encompass any such furthercomponents that are readily apparent to those skilled in the art oftobacco and tobacco-related or tobacco-derived products. See, e.g.,Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp.(1972) and Leffingwell et al., Tobacco Flavoring for Smoking Products(1972), the disclosures of which are incorporated herein by reference intheir entireties. It should be noted that reference to a flavorantshould not be limited to any single flavorant as described above, andmay, in fact, represent a combination of one or more flavorants.

Some possible components that may be included in an aerosol sourcemember cartridge are provided, for example, in U.S. Pat. App. Pub. No.2014/0261495 to DePiano et al., which is incorporated herein byreference in its entirety. Additional components that may be included inan aerosol source member cartridge and details relating thereto areprovided, for example, in U.S. Pat. Pub. No. 2015/0335071 to Brinkley etal., filed May 23, 2014, which is incorporated herein by reference inits entirety. Various other components that may be applicable to anaerosol delivery device according to the present disclosure can bechosen from components described in the art and commercially available.Reference is made, for example, to the reservoir and heater system forcontrollable delivery of multiple aerosolizable materials in anelectronic smoking article disclosed in U.S. Pat. App. Pub. No.2014/0000638 to Sebastian et al., which is incorporated herein byreference in its entirety.

With regard to any of the implementations described above, the overallfunction of a device may vary, based on the requirements of a particularapplication. In one implementation, for example, once an aerosol sourcemember has been inserted into the device and with the heating assemblyin a heating (e.g., closed) position, the device may be initiallyactivated using a switch and/or pushbutton as described above.Preheating may be the next operation and may occur for approximately20-30 seconds. Within the preheating period, a particularcurrent/voltage passing through the heating assembly (e.g., the heatingelements) may cause the temperature of the heating elements to reachapproximately 100-120° C. A temperature sensor (e.g., a resistancetemperature detector) may be included so as to control the preheatingtemperature so that it does not surpass the desired preheatingtemperature.

After preheating is finished, individual heating elements may beactivated, which in some implementations may be triggered by a user bydrawing air into the device. In some implementations, the heatingelement temperature may crest at 250-350° C. during each draw. Someimplementations may include pressure sensors to measure the pressurechanges in the device to activate one or more the heating elements withregard to each air drawing. The device may further be configured so thatpower can be switched/controlled between/among the elements through thecontrol component using one or more stimuli. For example, in someimplementations the stimuli may relate to the number of puffs and/orother parameters, such as, for example, temperature changes in theheating elements.

In some implementations, a heating element may be energized subsequentto a preheating period triggered by a first draw on the device. Theheating element may be energized again for second and third draws on thedevice. The number of times that each heating element is energized canbe adjusted depending on the total number of the heating elements,resistance, and size of the heating elements, and the electric power ofthe heating elements. After a segment of the aerosol generatingcomponent associated with a heating element has been consumed, anotherheating element, such as, for example, the next heating element, may beactivated. In some implementations, the device may be configured so thatpower may be controlled to a subsequent heating element every time theuser switches on the device. In some implementations, a heating cyclemay be reset to zero and may start over after energizing the lastheating element in the series and/or when the aerosol source member isremoved or inserted into the device by a user. Additional functionalcharacteristics that may be applicable to the present aerosol deliverydevice are described in U.S. patent application Ser. No. 15/976,526,filed on May 10, 2018, and titled Control Component for SegmentedHeating in an Aerosol Delivery Device, which is incorporated herein byreference in its entirety.

It should be noted for any of the aerosol delivery device describedabove, the same device may be configured to accommodate either anaerosol source member having a solid or semi-solid aerosol generatingcomponent (e.g., similar to the aerosol source member 408) or an aerosolsource member having a liquid or semi-liquid aerosol generatingcomponent (e.g., similar to the aerosol source member 508). In such amanner, the control component of that particular device may beconfigured to adjust or control various parameters (e.g., heatingtemperatures, heating times, etc.) to accommodate the particular aerosolgenerating component used with the device.

Although the various figures described herein illustrate the housing orhousing portions and the aerosol source member in a workingrelationship, it is understood that the housing or housing portions andthe aerosol source member may exist as individual devices. Accordingly,any discussion otherwise provided herein in relation to the componentsin combination also should be understood as applying to the control bodyand the aerosol source member as individual and separate components.

In another aspect, the present disclosure may be directed to kits thatprovide a variety of components as described herein. For example, a kitmay comprise a housing or one or more housing portions with one or moreaerosol source members. A kit may further comprise a housing or one ormore housing portions with one or more charging components. A kit mayfurther comprise a housing or one or more housing portions with one ormore batteries. A kit may further comprise a housing or one or morehousing portions with one or more aerosol source members and one or morecharging components and/or one or more batteries. In furtherimplementations, a kit may comprise a plurality of aerosol sourcemembers. A kit may further comprise a plurality of aerosol sourcemembers and one or more batteries and/or one or more chargingcomponents. In the above implementations, the aerosol source members orthe housing or housing portions may be provided with a heating assemblyinclusive thereto. The inventive kits may further include a case (orother packaging, carrying, or storage component) that accommodates oneor more of the further kit components. The case could be a reusable hardor soft container. Further, the case could be simply a box or otherpackaging structure.

Many modifications and other embodiments of the disclosure will come tomind to one skilled in the art to which this disclosure pertains havingthe benefit of the teachings presented in the foregoing descriptions andthe associated drawings. Therefore, it is to be understood that thedisclosure is not to be limited to the specific embodiments disclosedherein and that modifications and other embodiments are intended to beincluded within the scope of the appended claims. Although specificterms are employed herein, they are used in a generic and descriptivesense only and not for purposes of limitation.

1. An aerosol delivery device, comprising: a control body having anouter housing; an electrical energy source located within the housing; acontrol component operatively connected to the electrical energy source;a heating assembly operatively connected to the control component; andan aerosol source member that includes an aerosol generating componentconfigured to be positioned proximate the heating assembly, wherein theheating assembly comprises a series of heating members, and wherein eachheating member is independent and distinct and configured to heat asegment of the aerosol source member.
 2. The aerosol delivery device ofclaim 1, wherein the heating assembly comprises a moveable jaw and astationary jaw, wherein the heating members are located on the moveablejaw, and wherein the moveable jaw is configured to move between an openposition, in which the moveable jaw is spaced from the stationary jawand the heating members are not in contact with the aerosol sourcemember, and a closed position, in which the series of heating members ofthe moveable jaw are in contact with the aerosol source member.
 3. Theaerosol delivery device of claim 2, further comprising a receivingsleeve configured to receive the aerosol source member, and wherein thereceiving sleeve is located, in the closed position, between themoveable jaw and the stationary jaw.
 4. The aerosol delivery device ofclaim 2, wherein the series of heating members comprises a series ofheating pins that are configured, in the closed position, to passthrough the aerosol source member and to create an electrical connectionwith a series of corresponding connectors located on the stationary jaw.5. The aerosol delivery device of claim 4, wherein the heating pins havea substantially cylindrical shape.
 6. The aerosol delivery device ofclaim 2, wherein the series of heating members comprises individualheating elements that are configured, in the closed position, to extendinto the aerosol source member.
 7. The aerosol delivery device of claim6, wherein the heating elements have a substantially blade-like shape.8. The aerosol delivery device of claim 2, wherein the moveable jaw isconfigured to be automatically moveable.
 9. The aerosol delivery deviceof claim 2, wherein the moveable jaw is configured to be manuallymoveable.
 10. The aerosol delivery device of claim 1, wherein the seriesof heating members comprises a series of individual heating elements,wherein the heating assembly comprises two or more moveable jaws,wherein one or more of the heating members are located on each moveablejaw, and wherein the moveable jaws are configured to move between anopen position, in which the moveable jaws are spaced from each other andthe heating members are not in contact with the aerosol source member,and a closed position, in which the series of heating elements of therespective moveable jaws are in contact with the aerosol source member.11. The aerosol delivery device of claim 10, wherein the heatingassembly comprises three moveable jaws, and wherein the heating elementsof each moveable jaw have a staggered configuration with respect toanother moveable jaw.
 12. The aerosol delivery device of claim 10,wherein the heating elements are configured, in the closed position, toextend into the aerosol source member.
 13. The aerosol delivery deviceof claim 10, wherein the moveable jaws are configured to beautomatically moveable.
 14. The aerosol delivery device of claim 10,wherein the moveable jaws are configured to be manually moveable. 15.The aerosol delivery device of claim 1, wherein the heating assemblycomprises a series of fixed heating elements that are located adjacentthe aerosol source member.
 16. The aerosol delivery device of claim 15,wherein the aerosol source member comprises a removable cartridge andthe aerosol generating component comprises a tobacco or tobacco-derivedmaterial.
 17. The aerosol delivery device of claim 15, wherein theaerosol source member comprises a removable cartridge and the aerosolgenerating component comprises a liquid aerosol precursor composition.18. The aerosol delivery device of claim 17, wherein the cartridgedefines a series of atomizer chambers, and wherein a separate wickextends through each atomizer chamber.
 19. The aerosol delivery deviceof claim 18, wherein each of the fixed heating elements is configured tobe located proximate a corresponding atomizer chamber.
 20. The aerosoldelivery device of claim 1, wherein the heating members are configuredto be independently controllable.